e46 front swaybar

[nando]

OK, here are the two options I'm proposing.

First, some pictures of the brackets - "generic" on the left, stock E30 ix on the right:






here you can see how the generic bracket lines up pretty well with the E30 ix bracket:


Option 1 - modify the "generic" bracket to fit the E30 ix subframe

Basically, cut off one of the bolt-through mounting tabs, and bend up a new tab that fits into the ix subframe. The bushing would need modified slightly - there's a little "gusset" on the subframe in the corner of the bushing. that would be pretty simple with a jig and a router.

as far as the tab, it would have to either be bent from the existing material left on the bracket or welded on. I think there's plenty to bend a new tab from the existing material. But who can do it and how much would it cost? I'm going to have to search around a little, there may be a local shop who could do something like this but to be honest this area pretty much sucks for any sort of custom fab work..

Option 2 - use the stock E30 ix mount bracket, and use a custom bushing.

It would have to be molded to the ix bracket shape, which is not overly simple. also, with a 23mm bar, there'd only be about 5mm of bushing material left around the swaybar. I've mentioned I'm not very comfortable with this, but maybe it would work. Of course with a custom bushing you need a custom mold - which might be cost prohibitive.

Another alternative would be to ream out a stock bushing. I might give that a shot with an old one to see who well it might work.

the E46 bushing is far too bulky and would never fit. you'd have to make a totally custom bracket anyway - probably not cost effective. plus the bushing is really soft.

of course you're free to do whatever you like - I'm just thinking if I can think of a way to make it basically bolt on, a few people might be interested. I'd rather have something where the bushing could be easily and cheaply replaced, rather than something one-off that I won't be able to replicate in 10 years.

or maybe George Graves can print us one up on his fancy new 3D printing machine. ;)

[nando]

that may be a viable option - it depends on which is more cost effective, a customized/modified bracket, or a custom bushing.

I wanted the 21mm bar, but ended up being sold the 23mm bar instead. oh well..

[Northern]

With a 21mm bar, 7mm of material sounds more than sufficient to me.

[nando]

E46 bushings wont work. They are HUGE, bulky, and soft. Even if they could work, i wouldn't want to use them.



E46 on the left, generic aftermarket (Energy Suspension) in the middle, and E30 ix on the right. The aftermarket bushing and bracket are most similar to the E30, and will be easiest to adapt.

The E30 bushing is only 34mm at the narrowest part, which only leaves ~5mm of bushing material if you reamed it out. No bueno.

[Northern]

If we can get a custom bracket that fits standard e46 oem and aftermarket bushings, that sounds a lot better than the reamed out ix setup.

[nando]

I have some pics of what needs to happen to make a custom bracket. will post Tuesday..

[stonea]

I'd be down.

[Nisse Järnet]

Yeah why not :-)

[imwhyteyo]

maybe if we could get 5-10 people and a set of brackets this could happen. Used E46 front swaybars only cost ~$50 - and a brand new one is only about $100. I think the bushings are about $25. even if modifying the brackets cost $50 it would still be pretty affordable.

any of you other guys thinking of this? i just received my ebay "special" front bar, with brackets and bushings for a mere 28.99 shipped. and im soo ready to get this thing in.

[nando]

Just had a look at it again - I really don't think the stock bracket will work even with a custom bushing.

there's just not enough room for any significant material - even the stock bushing is pretty thin, now you're taking about 7mm out of it, you have maybe 2-3mm of bushing material leftover. Also, cutting it down wouldn't be simple anyway, as the ix's bracket has a really odd contour that the bushing fits into.

However, the brackets that came with my 23mm bushings are *really* close to the same dimensions as the E30ix brackets. all that would need to happen is have one end modified so it would "clip" into the subframe like the stock one. Possibly the bracket it comes with could be cut and bent to have the tab needed to fit like stock (looks like there is lots of material). the bolted end will already line up perfectly (the brackets have a slotted hole). Probably would need to have them powdercoated, as the zinc coating would be damaged.

you'd still have to modify the bushing slightly to clear a little ~3/8" fillet on the subframe (near the corner of the bushing, opposite of the "clip" in the subframe) but that would be pretty easy to do with a file or utility knife.

there aren't a lot of "custom" shops around here but I know maybe a couple that could do this (diesel truck shops are my best hope). maybe if we could get 5-10 people and a set of brackets this could happen. Used E46 front swaybars only cost ~$50 - and a brand new one is only about $100. I think the bushings are about $25. even if modifying the brackets cost $50 it would still be pretty affordable.

[imwhyteyo]

true, i understand that. im going to order one off ebay tonight, see about doing some personal research myself. let me know what you turn up for brackets and such.. maybe i can talk to my machinist across the hall from my garage spot, hes extremely crafty when it comes to odd custom bits. cant beat having your own personal machine shop 20ft. from where you wrench ;)

[nando]

Or it will bind. Dunno! I'll look into it.

[imwhyteyo]

wouldnt you think a thin bushing may not be so bad of a thing? perhaps as long as the bracket was sturdy enough, it might actually provide a more firm support under stress, allowing for less flex? if you might understand what i mean

[nando]

I know a couple people maybe - if anyone else has suggestions, I least have a set of stock brackets and the "generic" poly bushing brackets to work from.

the poly bushing would *almost* fit the stock bracket but you'd have to remove too much material for it to work.

another alternative could be custom bushings but I just think they'd be too thin.

[imwhyteyo]

id definitely purchase these brackets if they were made, do you know anybody who might have a means of fabbing a few up..? perhaps getting a group thing going we could really push the effort and start getting this done right!