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Min · Posted: Sat Aug 15, 2009 4:25 pm Post subject: Plastic Sway Bar Bushings

Pocketscience wanted some bushings, so I made some for him, he wanted me to document the process though, so, here it is.

First I split the plastic down the exact middle with the 1/16th thick slitting saw on the milling machine.

Then I finished the cut with the bandsaw in vertical mode.

Just a picture of them after they were split.

Back to the milling machine to face the split pieces perfect flat.

Cut the outside first, I used the partoff tool for this portion. It works well cutting shoulders in plastic.

Then time to drill out the center, so I could fit the boring bar in the hole. The hose clamps are to keep the split halves of the bushing together while I machined them.

Boring out the center to the required size (23mm)

Then back over to the bandsaw to trim them down to their final length.

All done.

Final Test fitting, I have the same size of swaybar as pocketscience does, so I just fitted them up to my car to insure they fit properly.

Now I just have to finish the end links and its all done.

Min
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morghen · Joined: 21 Jan 2005 Posts: 9102 Location: Romania

they look good, i would have made those shoulders a tad bigger but i think its all good.
i'm wondering how strong the plastic is..and will the material compress or not in the areas that it will be the "wear area"

i've made myself a bushing out of this kind of plastic for the shifting linkage and its now 2-3 months since its in but i feel like the shifter is sloppy again...could be me or could be the plastic giving in.
i'll check and report back.
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Min · Posted: Sun Aug 16, 2009 1:25 am Post subject:

ideola · Joined: 01 Oct 2004 Posts: 15550 Location: Spring Lake MI

Nice work Min! I envy your skills and equipment

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Min · Posted: Sun Aug 16, 2009 11:12 am Post subject:

pocketscience · Posted: Sun Aug 16, 2009 2:08 pm Post subject:

Nice! My sway bar can't wait to meet them!!

G.
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