Snap - there goes another sway bar link!

[Ron Katona <ron3b@xxxxxxxx>]

Was it Steve D'Gerolamo who was asking about sway bar links the other
day? Well, I broke a rear one at an autocross today on my 318ti. This is
of more interest to E30 owners since the rear is an E30 clone.

I heard a thunk on my last run and kind of plowed through the last turn.
I thought I just hit a bump and overdrove the final corner. Didn't
notice something was broken 'till I drove home and heard the clanking
over bumps. Interestingly, I swore it was coming from the front. Jacked
up the front and examined everything - no problems (scratching head).
Jacked up rear for S's & G's... Bingo!

I have aftermarket adjustable bars and installed (welded) supporting
brackets under the mounting tabs on the trailing arms when the bars went
in. The tab on the trailing arm didn't break - it was the U shaped
bracket that connects the sway bar end link to the trailing arm.

These pieces look under-engineered both front and rear; I don't want to
replace the broken one with a stock piece. The bracket looks quite
simple to reproduce. It's just a U with a hole in the bottom and each
side. I'm going to look for a local machine shop to produce a stronger
piece.

Any tips on what type of metal is best for this application? I think
there needs to be some flexibility in it - too stiff and it might tend
to crack. The old one fatigued at the bottom of the U near the bolt
hole.

Any leads on a good DC area machine shop? Anyone have the means and
skill to try to produce one of these at home? Steve, did you get any
leads on aftermarket suppliers?

If I get the rear done, I'll try to do the fronts as well since I'm sure
they'll fail eventually. Whoever does it, I'll ask that they keep notes
and drawings so that others can reproduce the parts. I'd also suggest
replacing the stock pieces every year if you do a lot of autocross &
drivers' schools and have aftermarket sway bars (maybe even if you
don't). Glad this didn't happen to me at 90 mph in turn 4 at Summit
Point last weekend.

BTW, the car understeers like a rented Neon with no rear bar mounted (I
removed it to keep it from hitting the axle).
- -- 
Ron Katona

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