Shorten a sway bar?

[Chevette]

Has anyone ever shortened a sway bar? I have a 33mm front sway bar that is too wide for my suspension. I need to know if one could cut it in the middle, remove 2" and weld it back together (using an insert), without ruining the integrity of the bar. I have the means to do it, I just wonder if it will work properly after being modified like that. Any help would be appreciated.

[1project2many]

I need to know if one could cut it in the middle, remove 2" and weld it back together (using an insert), without ruining the integrity of the bar.

Nope. Welding the bar in the center is a bad idea to begin with as stress will become concentrated at the weld. But when you consider that you'll take any heat treatment and stress relieving out of the bar, you'll end up with a part that's very different from what you intended.

[Chevette]

Originally Posted by 1project2many

Nope. Welding the bar in the center is a bad idea to begin with as stress will become concentrated at the weld. But when you consider that you'll take any heat treatment and stress relieving out of the bar, you'll end up with a part that's very different from what you intended.

That's what I was afraid of. Thanks for the help. Anyone need a C6 Z06 sway bar? Just kidding.

[mr48chev]

The sway bar is actually a type of a spring and would be hard to modify. A spring shop might be a be able to do it correctly though.

[_Ogre]

the center of the swaybar is spring steel and does most of the flexing
i don't think you could cut and weld it

the sway bar that came with the 86 trans am rearend centered my frame
i heated the ends red hot and bent them out to clear the frame
no problems in 10,000 miles
bad pics but this is what i have





the bracket towards the bottom of the pic is for the link to the sway bar

[Chevette]

Originally Posted by _Ogre

the center of the swaybar is spring steel and does most of the flexing
i don't think you could cut and weld it

the sway bar that came with the 86 trans am rearend centered my frame
i heated the ends red hot and bent them out to clear the frame
no problems in 10,000 miles
bad pics but this is what i have





the bracket towards the bottom of the pic is for the link to the sway bar

That just might work, Ogre. In my case I would have to heat it at the turns and bend it inward. An inch at each end and move the sway bar forward on the chassis. Good thinkin' man! Thanks for the help.

[_Ogre]

that's what we're here for