Plastic chassis front end

[bronco100]

Thanks Ford for making plastic tabs off the chassis that are 1mm thick so they break if a stiff breeze comes along. How am I supposed to fix this. (Passenger side pic for reference of how it’s supposed to be)

 

[bronco100]

Looks like I might have to replace the entire piece unless I want to try and plastic weld it back on (which I don't because it'll just break again).

https://www.carparts.com/details/Fo...018/EcoBoost/4_Cyl_2-dot-3L/R-RF25020002.html

What are the aftermarket options for this?

I notice Steeda (and many other companies such as BMR, Kenny Brown, etc.) made options for S197 (https://www.steeda.com/mustang-radiator-supports) - so what's the hold up with S550?

 

[Stangra]

I'm guessing that part is made of polypropylene, similar S197 parts are. Polypropylene can be difficult to bond but with a quick search I found this stuff which sounds like it might do the trick. If you go this route don't just glue the fractured edges together. The break is on a flat surface so you if you can find find some suitable material, make an overlapping plate to bond onto the backside too. If this stuff is as effective as claimed I doubt it'll ever break in the same spot again.

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www.gluegun.com

 

[mavisky]

Only real option is factory replacement part. Contact The Parts Farm who part out mustangs all the time. May have a car that got rear-ended that has one that's in good shape.

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[TMSBOSS]

Don’t blame Ford for making vehicles which are lighter when the government mandates mileage standards and performance minded owners want to go faster.

What you could do is find a piece of plastic the same size, remove the bolt and glue it over the cracked piece with an epoxy or JB plastic weld.

BTW, the “Chassis” is still made of metal.

 

[bronco100]

Don’t blame Ford for making vehicles which are lighter when the government mandates mileage standards and performance minded owners want to go faster.

What you could do is find a piece of plastic the same size, remove the bolt and glue it over the cracked piece with an epoxy or JB plastic weld.

BTW, the “Chassis” is still made of metal.

I have plastic welded it for the moment, we'll see if it holds. Regardless, it doesn't make any sense - the radiator support bracket is metal - but this particular tab is plastic - and yet they are the same part? If they just made it a separate plastic piece that screws or clips onto the metal piece, there wouldn't be a problem, as I could replace just that one piece. Making them all one piece is the epitome of "non-repairable design". There's no good reason for it.

 

[bronco100]

Also, I still don't understand why there's like 20 aftermarket options of radiator supports for S197 and none for S550. Have companies stopped developing new products for Mustangs? Is it still too early (9 years since S550 debut maybe not enough)?

If I have to buy a new factory radiator support - I'm 3D scanning it and CAD designing an aluminum version that I'll charge like $3k for and I'll have a monopoly on the market since no one else seems to want to make one.

 

[mavisky]

Also, I still don't understand why there's like 20 aftermarket options of radiator supports for S197 and none for S550. Have companies stopped developing new products for Mustangs? Is it still too early (9 years since S550 debut maybe not enough)?

If I have to buy a new factory radiator support - I'm 3D scanning it and CAD designing an aluminum version that I'll charge like $3k for and I'll have a monopoly on the market since no one else seems to want to make one.

I imagine it comes down to complexity, cost, and improvement potential.

 

[Mike_FL]

I think a lot of the plastic front end comes from the need for the mustang to pass European pedestrians safely laws as the S550 is the first Mustang sold around the world

 

[TMSBOSS]

I have dome a few plastic repairs. I have the best success with a plastic epoxy like JB weld and a plastic “Doubler”, a piece of plastic larger that the break, bonded over the break.
The European standard point may be real. My daughter had a low speed incident with the front of her Focus RS, all European engineering. Most of the front end came to me for repair in trash bags.
The head lights at over $1k retail. One had a single mounting tab cracked off. Epoxy and a doubler on top and steel rod underneath saved over $950.00.