While competing in a rally back in August the 1967 Sunny was pulling to the left under braking.  It got worse during the event but somehow we won anyway (very low key event so don't be too surprised).  We thought it was brakes but as soon as I started removing the front wheels I found the real cause.  The little tower on the left hand side that comes up from the front rails that the top suspension arm mounts on had broken off.  All that was holding it on was the bolt to the outer end of the cross-member.

The plan is to bend everything back to close to the right shape, weld it in while comparing position to the other one then plate over the weld and further down the rails.  Then strengthen the RH side.  I will probably have to remove the cross-member to do it.
 
Now how do I get rid of the extra posts I made?
 
Mark

I don't believe that rust has had any part in it.  Just the twisting from the braking force (PB510 discs) and keeping the wheel located in the one vertical plane.
 
It's the same car that I finished building in 1998, it's only showing about 7000 miles since then but a lot of it has been hard driving on dirt.
 
The cross-member is now out so the clean up can proceed then welding, painting and re-assembly.
 
Mark

can you please state what work you did for your front disc brake setup to work
Im always looking out and so are others on alternatives

For re-inforcement I am thinking of:
.   two strips of angle (1-2mm thick) on top of the rails against the tower and parallel to the cross-member;
.   two strips (10mm wide) of flat running down the towers onto the rail maybe going under as well;
.   two wider strips running down the outside joins and going under the rail.
 
I am happy to recieve any advice (and piccies/sketches).
 
Mark

I hope I am thinking about this right.
 
What about making the worlds smallest "Strut Brace" to connect the crossmember to the suspension mount?
It would replace some camber shims at the top end and mount between the engine mount and crossmember at the other.

I can report from the rally that there are a lot of hills around Powelltown.  The A10 was spinning at 7000rpm for much of the night in second gear.  We finished but down in 7th place.  Stanza in first then a couple of Golfs, a 205GTI, a Corolla (very embarrasing) and a 2L Escort.  We beat the next 14 as well as the 10 that didn't finish.  The only re-assembly problem was one of the gearbox mount bolts not being tight.  Now I have a very long list of improvements before the next event which is back on flatter country.
 
Mark