Lower Control arm cam tab gussetts

Does anybody have any advice on replacing just one of the cam tab gussetts? Everywhere I look comes with a kit of like 8 gussetts AND you also have to weld the tabs on to the gussett first before welding the gussett on the frame. I guess its not a huge deal to weld the tabs on first. It would just be nice to buy a gussett ready to go with the tabs already on it. Then all I have to do is weld the gussett to the frame. One of the tabs broke off when I was trying to install my own lift kit, so I just need to replace the one gussett. Not sure how universal these gussetts are, but I have a 2019 tundra.

 

Photos would be helpful here for best analysis.

 

I just welded a little block of 1/4" steel where the tab used to be

 

Interesting. And it held up? I suggested the same thing to my welding teacher at my school and he said the weld wouldn't be strong enough to hold.

 

I'll hold back any comments to your welding teacher the stock cam tab is what, bent 11ga? Nearly anything is stronger than that. iirc I did like a 1" tall, 0.5" wide piece and welded the top, outside, and bottom (in a C shape essentially) so the inside portion the cam presses against was not welded. That's a lot of weld area, and the cam isn't applying very much force. Figure 2" of weld, 0.125" throat if it's a shit tiny weld, 70ksi wire which is roughly 35ksi in shear. That little shitty welded piece can react nearly 9000lbs before it's ripping off. And ideally the cam tab itself is not reacting load, it sets the alignment and the clamping force from torquing the bolt creates enough friction that the bushing doesn't move (again, IDEALLY). But at the end of the day all of that is still a hell of a lot stronger than the dinky bent tab that's on there stock. And if you don't think that's good enough, cut a bigger piece and have more weld area. The total chaos and aftermarket gusset kits I'm pretty sure are literally the same thing, just a little 1/4" bar welded to brace the tab.

 

So this tab I circled is what's broken off. Is it necessary to take off the bolt and lower control arm in order to weld the tab on, or were you able to weld it on without removing the bolt?

 

^^^^^ This. Exactly this. Just weld on a bar in place of the broken tab. If it doesn’t work, you can always remove it. In order for the TC tabs to be installed, all of that has to come off anyways.

 

I didnt remove anything to do it. In my case the tab had been flattened over, but the cam wasn't laying over it (not sure how or why it got flattened). I cut the flattened portion off, wire brush, weld on, paint, usual shit. The only instance I see you having issue is if the cam has slid over the messed up tab so the cam is now not sitting where it should be, in that event you'll want to loosen the cams and rotate them or move the control arm so the cam is sitting back where it should be, then same process. The cam is a loose fit in the little channel it sits in since it needs to be able to rotate during alignments, so don't go crazy making the new tab squish the cam to the point the cam can't spin anymore.

If I remember in the morning I'll grab a picture, I think I replaced a few that looked a little boogered when I was under there.