Engineering a sway bar

[TwoJ's]

Also for anyone who is relatively local, do you know where I could get my car on corner scales? I would really like to know F/R and L/R weight bias.

[TwoJ's]

This is my new favorite thread - got to come back when I have time for re-read - interesting stuff.

TwoJ's - is that U-dub?

Thanks. I am actually at Central Washington U, a much smaller school.

I am going to send you a PM right now, I need a hand with some electrical stuff for instrumentation.

[328ijunkie]

Are E30 stock sways hollow? My E36 ones arent....

[m3clutch]

legit. I too am ME...and I love SolidWorks!!!! i think it's great that we can sit at our computer and properly dimension, trace, draw, etc. what ever our hearts desire and then test them virtually. although trivial to your project, I'm in the process of making some simple spacers for funzies.

[SpecRaceM5]

IE will keep me from being profitable because they likely have their shit made in China.

Their swaybars are actually manufactured in the US.

I do agree though that it is hard to be competative in the e30 market (or BMW market for that matter) because either A. you have to have a name for yourself which takes time, or B. you have everything made in China and offer the lowest price and still have somewhat of a name for yourself.

Regardless, I think what you are doing is pretty bad ass. I'd be curious to see the rest of your mounting sollution as all aftermarket swaybars for these cars tend to have some sort of chassis reinforcement.

I think if you could figure out a unique way to design your bar that you can truthfully sell as being better than the competitor and you can back it up with good customer service, you may be able to break into the market as a premium, niche product.

I kinda wish you would have stuck with your original project idea. Tubeular control arms are just plain bad ass! Keep up the good work!

Cheers,

Brian

[george graves]

This is my new favorite thread - got to come back when I have time for re-read - interesting stuff.

TwoJ's - is that U-dub?

[Skafrog]

Now that I get to thinking about this, I am not sure that I have seen GC's version of the adjustable sway bar. Do you have a link or a picture that will show the "sliding mount"? I have seen some like IE's adjustable sway bar that simply has three holes in it, but this is not a desirable solution and is just an easy way out. I would be interested in seeing what this sliding mount is that you're talking about.

I quoted this response, but your points are valid on your previous post about selling them. However, if you do decide to market a bar with a sliding adjustment, I would be interested.
In regards to the swaybar mounts, this is ground control's e46 m3 swaybar setup. As far as I know, no one makes a kit such as this for e30's. Obviously, one would need to convert to m3 style swaybar links.

[LivingLegend06]

Not that I know dick about your school shit, but it seems you could thread the inside of that tube and make the ends thread in, like a tie rod end.

It's best to avoid putting threads in bending.

I'm curious to see what kind of calculations you did to determine the roll rates and weight transfer.

[87-325ic]

sweet work!! Just goes to show that anything is possible if you want to do it.

[TwoJ's]

First off awesome out on the project!

Are you getting your BS or MS in mechanical engineering?

I'll be going to FSU to get my BS in ME..... Can't wait to be designing projects like this..... Love all the calculations and time that goes into things like that...

Your draft of the parts is completely diff from how im learning how to draw lol (measurement layout wise)

Yeah, I think I said in there somewhere that the dimensions needed to be fixed. I just threw them on there and printed off a copy to take down to the machine shop with me.

sliding mount could be accomplished much easier by using a clamping design on the bar itself. rather than having to make all new ends for it. :)

Interesting idea, but I doubt it would work out too well. There needs to be a flat surface to bolt to, and the wall thickness is only .120. It's not like making some kind of ends will be hard.

Not that I know dick about your school shit, but it seems you could thread the inside of that tube and make the ends thread in, like a tie rod end.

This is an interesting idea. But I really think that it is just easier to weld them in there. No bull shit cutting threads on the lathe.

And this is for a class for mechanical engineering? Interested in taking same major, getting emails from colleges already. Mind if I ask about the classes and what kind of stuff you do, and how its applicable (i.e. where do you plan to use your engineering, motorsports, you mentioned suspension analysis). Cool project good work on it too!

That's cool man. I would say that you'd be good for a ME program if you like math and physics. That is just about all there is to it. I am getting a math degree at the same time, so math comes easily to me. Don't get me wrong though, there are definitely people in my program that are not great at math, but they just have to try harder at some things. No biggie.

A BS in Mechanical engineering is actually a pretty broad degree. It covers anything from HVAC design to aerospace engineering. I specifically would love to design suspension systems. I think I would like going to work if I had that job. I've also always had an interest in aerospace, so I would love to work for Boeing for 5 or so years. Basically you can do a ton of jobs with an ME degree -- you just may have to learn a few more things once you realize what you will be specializing in.

[StereoInstaller1]

Hey, that is cool! A heim joint stuck on the end of a sway bar means LOTS of choices in how you could make the end link!

[mojorising]

Great project. Its great to see a well thought out project like this with engineering actually involved instead of just imagineering. Maybe I missed it somewhere but are you going for a stock rate or did you change it? Also, do you have any test in mind to test the sway bar rate once you get it done? How will this sway bar affect your vehicle roll rate and distribution? One more thought on those rod end mounts: double shear.

[learningcurve86]

Thank you. Where are you getting these numbers? I'm not denying anything, just curious. The TTT's, and input from a number of sources would disagree with you. There is definitely a stress concentration like I stated in the OP, but I believe that stress-relieving with an oxy-acetylene torch will be sufficient.

I had to do a lab last semester on some material properties, 4130 was one of them. In any case, I think I misunderstood briefly scanning the page (i like looking at pictures, i admit it lol). But in any event, regarding the bar itself, great idea to stress-relieve...

Not that I know dick about your school shit, but it seems you could thread the inside of that tube and make the ends thread in, like a tie rod end.

To add to this idea, and for other suspension tube related projects (camber adjusters, endlinks, etc...)

(rod ends, heim joins, pillowballs)

http://www.pitstopusa.com/Categories.aspx?ID=3380

(threaded suspension tubes)

http://www.pitstopusa.com/Categories.aspx?ID=3381

[StereoInstaller1]

Not that I know dick about your school shit, but it seems you could thread the inside of that tube and make the ends thread in, like a tie rod end.

[Jesse30]

sliding mount could be accomplished much easier by using a clamping design on the bar itself. rather than having to make all new ends for it. :)