Energy Sway Bar Bushings - Impossible?

[69fourspd]

I am having major issues with the Energy Suspension sway bar bushing kit.  I am using my stock sway bar with the kit that is a bracket which bolts to the k-member and bushings which bolt to the brackets.  The brackets are installed as per instructions and only needed a bit of massaging to fit right, but I believe they are installed correctly as the instructions show.  The problem I have is the bushings do not align with the bracket holes.  With the poly bushings, they are miles away since there is absolutely no give.  I read on the forum this setup works fine but cant understand how it is possible to align the bushings which are on the straight section of the sway bar but the brackets are angled a bit.  I have attached pics to show how the alignment is off. 

Any ideas or is this setup screwed? Anyone experience this issue? Thanks!

[Big Sugar]

Install the end links and temporarly support the front  of the swaybar with the mounts loose for mow, when the end links are tied into the control arm and the front of the bar is being supported ,centre the assembly out find a resting place along the k member for the mounts atay as wide apart as possible keeping the rubber on a flat part of the bar. If tou need to re-adjust the mounting location and redrill new holes thats just what you'll need to do to get it right ?   is it possible you have the bar upside dowm ?

More pics

Ron

[Back N Black]

I had no big issues with my install, but i did have to drill new holes.

[HPP]

Try swapping sides with the mounting bracket and see if things line up better.

[69fourspd]

Tried swapping the brackets and no better.  I had the links on loosely and the sway bar in the right position, but things just don't line up well.  I ended up putting the bolt closest to the rear in the bushing, then pushing like hell to get the front bushing bolt in.  I was bale to get the bolts started and with everythingthing loose tightened it up.  Not super happy with the result.  The bushing brackets did bend a bit as the urethane bushings have almost no give.  There is a bit of space on the outside of the bushing, but am not sure if this will affect anything.  Not the best looking part of my build, but I am not sure what I could have done differently.  Here are some pics of the bushing bracket bent and the gaps on the bushings. BTW, is there supposed to be almost zero clearance from the sway bar to the k-member on the outside of the bushings? Seems kind of close for my liking.

[69fourspd]

BTW.... If anybody is wondering why a tent is setup in my shop, I use this as my portable spray booth.  Keeps the place clean and can take it down in a minute.  I have a shopvac which sucks out from the bottom.  I mainly use this for powder coating as that dust can go everywhere. Good in a pinch for coating things like the Energy brackets which aren't coated well and would rust fast in my climate.  Can't beat it for $20 on ebay.   

[Big Sugar]

One picture shows the mounting bushing right at the bend in the swaybar, either your not centred or your busing mounts are to wide for the swaybar. 
    Try turning the bar over and see how it fits.  My new hotchkis has the front curve facing down as did my last swaybar.



Ron

[69fourspd]

Ron,
Thats right.  It is right at the bend.  Tried it upside down initially as well and no luck.  Bushings are still too far out.  This bar is the same one I took off which was on factory bushings.  Not sure if this sway bar is original, but it did fit previously.  Any bars out there with a wider stance at the bend that you know of? Also, I did use the factory holes to mount the Energy bracket adaptors. There is no other way of bringing the bracket in more without making all new holes which I do not want to do in my powder coated k-member.

[tan top]

addco bar mounting brackets are a similar set up  although made out of thinner gauge metal , put addco bars on mine ,  as Big S said put the brackets on the bar get the bar straight , then redrill holes or elongate factory hole as a necessary ,  or both  , forget now with out looking but could only use one factory hole each side , had to drill two new ones ,   best to  align the bar & brackets with the car on the ground  full weight on suspension  & level & with the bar link ends loose , mark where  the new holes are going to go etc  etc  , then jack it up , put on jack stands , drill holes , bolt bar up with brackets , so there is a tiny bit of movement  , lower car to ground , full weight on suspension , then tighten sway bar bolts & bar link ends

[Budnicks]

One picture shows the mounting bushing right at the bend in the swaybar, either your not centred or your busing mounts are to wide for the swaybar. 
    Try turning the bar over and see how it fits.  My new hotchkis has the front curve facing down as did my last swaybar.



Ron

yep  the hump should be down  , I don't know if the brackets will line up any better thou...