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Hello everyone I have a 1977 Ford F-250 Custom 2wd I’m going to try and explain this as good as I can so this truck was a farm truck and you can imagine it had its beating im currently doing a restoration on it and im currently rebuilding the front suspension and I got it all pulled out today and found out my radius arm mounts and the arms itself have taken a beaten the mount is warped and the threaded area on the arm (pictures below) so I’m honestly looking for a repair option I have heard this is common if I’m not mistaken correct me if I’m wrong but I’m looking to see what I can do at this point if there’s any good solutions thank you
Keep a couple of things in mind, first; if you restore this I'm pretty sure it will have a much easier life than it was raised with. Also the radius arm is just holding the I beam from moving forward and back. It's not a bearing surface that has to be perfect.
I would buy a new arm, but if you can't find a used bracket, just weld up the bad side of the hole and grind it, drill it, file it, whatever you can do to get it fairly round and call it a day.
X2 on I'd try and replace the radius arm mount bracket and the radius arm itself. But if I could not find either one, I would weld build up (just the worn out area) on the bracket and then grind, file, drill it back to its original round shape. Adding a piece of pipe inside it will change the inner diameter to much for the radius arm with the bushing to go back in.
I would try really hard to locate a replacement radius arm. If not, I would take it to a professional welding shop (unless you are a professional welder, like as in certified pipe line welder) and get those worn areas built back up. I would not just put some booger welds on that critical part of your suspension.
