Worn sway bar needing repair

[NeoJuice]

When I took apart the front suspension on my 1975 C10 I noticed significant wear on the ends of the sway bar where it connects to the lower control arms. The wear appears to be similar on both sides. I only have photos of the driver’s side right now but I’m wondering if this is something that can be repaired?

Would it be possible to have a shop weld and build the worn areas back up either by welding or TIG welding? Then reshape it to make the ends round again? I have new MOOG MOOK6169 1-1/16" bushings ready to install when I reassemble everything.

I have a small MIG welder and could potentially grind the area with a flap disc and fill in the worn spots myself. Would it be better to take the sway bar to a machine shop to ensure the ends are properly rebuilt and perfectly round? I’d prefer not to have the sway bar loose or moving around inside the new bushings. Any advice would be appreciated.

Here is a link to my build thread for reference:

https://67-72chevytrucks.com/vboard/...d.php?t=860348

[HO455]

They are not repairable. Mostly due to the cost. You would have to absolutely perfect welding done followed up by having the bar heat treated back to its original state. Any welding would destroy the factory heat treating. Its much cheaper and easier to get a used one. Suburbans till 93 used the same bars. You could also move up to an 1 1/4" bar for a noticeable improvement in handling.

[dagnabbitt]

I wonder what would cause that wear. I have never seen that before. Curious, because there might be some larger problem causing it.

[Dead Parrot]

Originally Posted by dagnabbitt

I wonder what would cause that wear. I have never seen that before. Curious, because there might be some larger problem causing it.

If the truck spent most of its life where OP is, would guess salty stuff accumulated there and did its thing over several decades.

Also 2nd on the idea that a welding repair attempt will change the metal properties for the worse.

In a pinch, could always clean, paint, reinstall and run as is. If it breaks, then replace. If it was being used that way recently, it might continue to work for many more years.

[SCOTI]

I would just buy a new/different 1.25" bar but not everyone can afford to. But.... Outside of the box thinking here, try some Epoxy. Mix up some epoxy to fill in the divots. Let it cure. Then file + sand to shape. Get it smooth. Paint if you want to. Try it out.

No impact on heat treatment & fills the voids. No harm if it wears & a cheap repair. If the bushings are lubed, I bet you get some decent miles w/o issue.

[NeoJuice]

Thanks for the input everyone. Yes the wear is probably from years and years of salt and sand on Canada roads in between the bushing and sway bar. The bushings were pretty much toast when I took them off. I thought of just cleaning it up, painting & reinstalling and run as is. The truck is just going to be a cruiser not a high performance speed demon lol.

I reached out to a friend who has some 70s C10s to see if he might have one in better shape so I'll see what he comes back to me with. I did a online search of the local pick and pulls and there is nothing older then 2000s pickups.

SCOTI that is a pretty good idea. If the surface was clean enough and there is plenty of cure time that might just work. I'll keep everyone up to date on what I end up doing. I was surprised myself at the wear. That's solid steal lol, how does water in a waterfall carve out rock or in a stream? same thing lol.

[HO455]

I believe these folks aren't too far away from you. They have several 67 to 87 Chevrolet & GMC trucks listed with sway bars priced at $40 bucks. At the minimum I would be swinging by just to see what goodies may be left on the truck they have listed as a 67 but obviously isn't a 67. Possibly a 5 lug rear axle to be had?

https://ipullupullcanada.ca/inventory-pricing/

[NeoJuice]

I pull you pull is not far from me. I've been there a couple times. They did have some C10s in there back in the fall but hey were so picked apart there was almost nothing left. I'll have to go check them out again once the weather warms up.