[s-cars] Crack in firewall - Steering Rack mount

[Jim Fleischer]

Hey guys, 

A few weeks ago, I noticed a click when turning the wheel...sounded like a relay "click" when it would happen, and it was intermittent, but often.  It ended up being a loose steering rack bolt that was "catching" on the firewall and making the sound.  So, I tightened the bolt and all was well until yesterday I heard the sound again, and I noticed a lot of flex in the mounting area.  Well, sure enough, the reinforcement area in the tirewell that had the loose bolt is cracked, and the firewall flexes about 5mm when turning the wheel.  So, I was thinking about taking the car to a welder/fabricator and having a piece made and welded in.  Anyone else BTDT and have some suggestions?  Thanks!

Best regards,

Jim Fleischer
'95 urS6 avant, needing some love