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General Discussion
Sway bar tabs bending?
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<blockquote data-quote="squeak12" data-source="post: 750577" data-attributes="member: 12742"><p>There are many ways to design a swaybar system and each will be somewhat unique to the application. While this design is viable, it isn't really ideal. Single shear at all points with additional leverage by having the studs, relatively low quality looking heims, thin mounting hardware, etc. Also consider that most offroad vehicles in this genre are sprung extremely light and ask a lot out of the sway bar in an attempt to maintain flex while avoiding body roll. That is a viable strategy if the situation dictates, but be prepared to beef up everything related to the swaybar. The loads have to go somewhere and the weights and forces offroad are quite different than other motorsport categories that have smoother load transfer on smaller tires, axles, less travel, etc.</p><p></p><p>All that being said, I'd boil it down to poor design/execution if you indeed aren't binding. Most just build to whatever they think is big enough with no regard to the weakest link, ultimate loads, or how the mounting points move throughout travel. Here it appears the mounting tabs either being too weak or loaded above their rated capacity... Be prepared if you increase the strength of the tabs (assuming binding is not occurring), the load will go elsewhere not disappear. Could end up breaking heims, bending links, or snapping a swaybar sooner which is actually to be expected on any swaybar, they are just torsion devices that fatigue over time.</p><p></p><p>I'd also add that it is possible that your pinion angle change may be binding the heims. I don't know what those are rated at versus the misalignment of the heims. Also consider that flexing out the suspension is not the same as if the entire suspension is under a dynamic load. Things bend and have inertia/momentum when actually loaded versus slowly moving through the travel. If you aren't near the limits it will be closer to the real thing, but quite a dangerous assumption to make if you fall in the other category.</p></blockquote><p></p>
[QUOTE="squeak12, post: 750577, member: 12742"] There are many ways to design a swaybar system and each will be somewhat unique to the application. While this design is viable, it isn't really ideal. Single shear at all points with additional leverage by having the studs, relatively low quality looking heims, thin mounting hardware, etc. Also consider that most offroad vehicles in this genre are sprung extremely light and ask a lot out of the sway bar in an attempt to maintain flex while avoiding body roll. That is a viable strategy if the situation dictates, but be prepared to beef up everything related to the swaybar. The loads have to go somewhere and the weights and forces offroad are quite different than other motorsport categories that have smoother load transfer on smaller tires, axles, less travel, etc. All that being said, I'd boil it down to poor design/execution if you indeed aren't binding. Most just build to whatever they think is big enough with no regard to the weakest link, ultimate loads, or how the mounting points move throughout travel. Here it appears the mounting tabs either being too weak or loaded above their rated capacity... Be prepared if you increase the strength of the tabs (assuming binding is not occurring), the load will go elsewhere not disappear. Could end up breaking heims, bending links, or snapping a swaybar sooner which is actually to be expected on any swaybar, they are just torsion devices that fatigue over time. I'd also add that it is possible that your pinion angle change may be binding the heims. I don't know what those are rated at versus the misalignment of the heims. Also consider that flexing out the suspension is not the same as if the entire suspension is under a dynamic load. Things bend and have inertia/momentum when actually loaded versus slowly moving through the travel. If you aren't near the limits it will be closer to the real thing, but quite a dangerous assumption to make if you fall in the other category. [/QUOTE]
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Sway bar tabs bending?
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