Well, I just broke my second front sway bar end link today. They really are a pretty stupid design being made partially of plastic and all! BTW, this was in 75 degree temps on very sticky concrete with the Comptech prototype bar (the adjustable one is VERY close to being ready to go.....) and Kumhos.

I know a couple of people have looked into alternative endlinks, but I didn't pay a lot of attention. Has anyone come across something that will work? I think I recall that heim joints won't work because the links are so short.

For the time being, I'll probably just buy a couple of stock ones so I have an extra on hand. However, I really think that something else is needed!

Ron

 

Ron:

Mine haven't broken yet, but it sounds like it might be good to have some spares on hand, just in case.

Please post the cost of the stock end links, when you get them.

Steve

 

It sounds like your are exceeding the max angle on the stock link. As you may remember I had the flat on my bar made aligned with the link rather than at stock angle to reduce the angle required so I could use standard rod ends. The stock bar end flats are not properly aligned, and comptech copied them. That's the fundamental problem.

I used 7/16 rod ends and aircraft grade hardware; no problems. I went 7/16 rather than 3/8 since everything is in single shear, so bolts carry a bending as well as shear load.

Several thoughts:

There are "high misalignment" rod ends that give more angle. Pegasus catalog lists for example. But my advice for source is to look up 'bearings" in the yellow pages and call a bearing distributor. They will have rod ends that you can hold in your hands and measure, plus full spec sheets. Prices are better than Pegasus as well. In Dallas I found at least three sources. One was near me so I stopped calling. With the aircraft industry in your area, I'd think there would be distributors.

Use robust spacers that give some bending support to the bolt (the pegasus safety capture washers work well) to move the rod end away from the bar, reducing the angle ( if there is room).

Use a longer link than stock, again reducing the angle. There is room to move the bar up without hitting the steering arm. Unfortunately this also moves the bar closer to the shock, which may be a problem with the comptech bar.

You might even lengthen the stock links: Cut shaft, slide into a longer tube and weld. (Use quick MIG or TIG so you don't fry the ball).

Or can Comptech or local shop weld a wedge of material to the bar end to create a flat aligned with the rod end? A little quick welding at the end won't mess up temper of the center working section. Unfortunately this also moves link closer to the shock.



[QUOTE]Originally posted by ronbauer
[B]Well, I just broke my second front sway bar end link today.

 

Ron... here is a pic of the replacement that I cooked up using rod-ends. They were binding and wearing and would have broken, so King made me some new ones (that look the same) using high-misalignment rod-ends.



These pics should give you an idea... I would take this photo to your local bearing store and they can give you the parts. Make sure you get the strongest possible bolts for mounting the rod ends. I would definitely do this rather than getting new stock ones.

See you in a couple days!

 

Thanks guys. Jason, is that link the same length as the stock one?

Ron

 

Yep... end to end is the same as stock. Plus, it's adustable in length (not that will adjust the stiffness of the bar). You just adjust it to the length of the stock one before installing it.

 

One more question, did you get everything at a bearing store? Is that just a washer between the swaybar and the link? Do you remember what the dimensions were on that?

I'm looking forward to seeing you in a few days. I'll be there Thursday night since I'm instructing at the Evolution school on Friday.

Ron

 

It was asked that I post the price of the stock links when I found that. They are $53.36 each. I'm going to try to go the bearing shop route, and will report back on how that goes and the cost!

Ron

 

[QUOTE]Originally posted by Jason Saini
[B]Yep... end to end is the same as stock.

 

[QUOTE]Originally posted by Gregg Lee
[B]It sounds like your are exceeding the max angle on the stock link.