Today I made some new seat belt shoulder brackets to replace my old system, which was coming undone slowly as you drove. That's bad. So it needed an overhaul. The new mount I made involves a plate, a solid threaded bolt, and washers.
I started with simple 1/4" aluminum stock, which I cut down to 3"x3" with a cutting wheel (not exactly machine-shop quality). I drilled 4 holes - one in each corner, and counter sunk them with a larger drill bit to allow the screw head to sit in. In the center I drilled a 1/2" hole, and on the back of the hole, counter sunk it so that the bolt head would sit flush with the back. I used the same bit, undid the clamp, and spun the brackets face down on the table with the drill to make a round pattern that looks like a brushed aluminum piece, and it looks cool. I did it on accident on the first piece, and repeated it on the second. I put a 1/2" bolt on there, and then used a nut and secured it against the face.
I took the washer out of the mix that you see in that image so it is just the nut resting on the aluminum. I do similar on brackets when I am working on wood rollercoasters, so I'd assume it will hold this in place too and be good without the washer. It also looks better.
This is the back of each, not cleaned up very good, but I sanded them after this. This shows how the bolts sit on the back.
I rounded the edges with a belt sander and made it look a little better.
They look ok. The big washer was just a placeholder for where the shoudler piece goes. After I get the system worked out better, I'm going to cut the bolt excess off and maybe find a finish nut for it.
It's a little rough, but still a work in progress. I used 4 heavy sheet metal screws to attach it. I think eventually I'll do rivets, as that's what some old car conversion kits use, but don't have any long enough to reach. The screws are real solid. I went to the other side of the car and yanked on the seatbelt as hard as I could a bunch. It still caught every single time, the cam stopped like it's supposed to, and the bracket did not move, or become loose.
Next is to cut off the excess when it stops raining, and find a cleaner looking nut to finish it better.
