DIY Extended Sway Bar Links.

by dbeutel42 in Workshop > Cars

2600 Views, 1 Favorites, 0 Comments

DIY Extended Sway Bar Links.

20160611_071626.jpg

After installing a 2 1/2 inch lift kit on my 1992 Jeep Yj, I couldn't get the sway bar links to hook up nicely. I shopped around and found lots of expended links but they were $60 and up.

I devise this solution which cost me all of $12. I already owned the Tap and Die set but if I had been forced to buy it for the job I would still have only spent $27

How Long Were They

20160609_171336.jpg
20160611_070258.jpg

I started by measuring the current length and finding this midpoint. I cut them in half using a right angle grinder and cut off wheel.

Cutting the Outside Threads

20160611_070631.jpg
20160611_070350.jpg
20160611_070417.jpg

I measured the outside diameter of the center section of the sway bar link. Checking a tap and die chart and I find I can use the 1/2 20 die from my harbor freight tap and die set. Conveniently there is a tap of the same size.

Cutting the Thread

20160611_070643.jpg

I used the die to cut the threads on the link halves.

20160609_171336.jpg
20160611_070745.jpg
20160611_070643.jpg

Again I referenced the tap and die chart and found I needed a piece of tube with a 29/64 id. I ordered a 12" piece of tubing 3/4 OD with 3/16 walls leaving 3/8 ID.

I cut the tube to 2 X 4 1/2 inch length

I chased the bore with a 29/64 drill bit, then tapped the internal threads.

20160611_070839.jpg
20160611_071032.jpg

I screwed everything together and measure the result, exaclty 2 1/2 inches longer.