Homemade ZJ Disconnects - JeepForum.com

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post #1 of 17 Old 02-28-2008, 09:02 PM Thread Starter
Cha Cha
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ZJ Homemade Swaybar Discos

Here are some low cost front swaybar disconnects that I made and thought I would share how I made them.
Items needed: atleast 6" of 1 1/4" X 1/8" steel, 2 Air hose couplers, 2 sway bar links, and some common sense.

Start out by cutting some 1 1/4" X 1/8" rolled steel cut into two 3" strips. http://i180.photobucket.com/albums/x...mmer070025.jpg After it is cut use your trusty 4lb. sledge to bend in half at a 90 angle. http://i180.photobucket.com/albums/x...mmer070026.jpg
Then drill two 1/2" holes in each side one for the mounting bolt and one for the air hose coupler that serves as the disconnect point. After the holes are drilled then put the female part of the coupler in on of the holes and either bolt or weld it on. http://i180.photobucket.com/albums/x...mmer070029.jpg
After this move on to the links if you have stock links I would cut off the threaded end and buy or make some thing to utilize the bushing so it will fold up and out of the way when disconnected. http://i180.photobucket.com/albums/x...mmer070032.jpg After you have cut it to the desired length, thread it or weld it into the male part of the air coupler. http://i180.photobucket.com/albums/x...mmer070034.jpg
Then put a fresh coat of rattle can on it in your desired color. Install and admire the simplicity and ease of use. http://i180.photobucket.com/albums/x...mmer070035.jpg


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post #2 of 17 Old 02-28-2008, 09:05 PM
tennesseewj
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mehh that's no good

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post #3 of 17 Old 02-28-2008, 09:06 PM
tsconver
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His links are all broke, lol

He fixed them and what a horribly dangerous bad idea. THose will brake under pressure and kill someone.

Speak softly and carry a big stick.

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post #4 of 17 Old 02-28-2008, 09:09 PM Thread Starter
Cha Cha
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They should be fixed.

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post #5 of 17 Old 02-28-2008, 09:10 PM
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Quote:
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They should be fixed.
you need to delete this before someone does it and gets killed, horrible idea.

Speak softly and carry a big stick.

We have room but for one flag, the American flag . . . We have room but for one language, and that is the English language . . . And we have room for but one sole loyalty...and that is a loyalty to the American people. T. Roosevelt 1919

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A few goodies
http://s257.photobucket.com/albums/h...umb55839/jeep/

2001 Kawasaki 1200 ZRX
A few Speed parts, fun to ride
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2006 Red Liberty
Wife's ride, pretty stock
http://i257.photobucket.com/albums/h...mage0008-1.jpg

http://www.cnc4x4.org/

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post #6 of 17 Old 02-28-2008, 09:27 PM
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cha cha,

I believe that you wouldn't die from this. However, your suspension mod could fail. If it does, it'll chose to do so at a very bad time. Why chance that? Yes, getting the proper parts is a bit more expensive but, worth every single penny of not having to worry that it will break.

Hunter

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post #7 of 17 Old 02-28-2008, 09:29 PM Thread Starter
Cha Cha
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These were designed for off roading, light road use and for ease of disconnection. I apreiciate the feed back and will reconsider my design. It was free anyway.

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post #8 of 17 Old 02-28-2008, 09:34 PM
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Quote:
Originally Posted by Cha Cha View Post
These were designed for off roading, light road use and for ease of disconnection. I apreiciate the feed back and will reconsider my design.
Do you drive the vehicle on the road? If so imagine going around a highway ramp at 55mph, the amount of force on the sway bar is way more than those disconnects were made to hold. Now in that same corner imagine it popping loose and you either roll teh jeep or have to counter steer to correct the sudden change in roll of teh body and cause a wreck. They are not safe and could kill someone.

Speak softly and carry a big stick.

We have room but for one flag, the American flag . . . We have room but for one language, and that is the English language . . . And we have room for but one sole loyalty...and that is a loyalty to the American people. T. Roosevelt 1919

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My Build Thread

A few goodies
http://s257.photobucket.com/albums/h...umb55839/jeep/

2001 Kawasaki 1200 ZRX
A few Speed parts, fun to ride
http://www.zrxoa.org/

2006 Red Liberty
Wife's ride, pretty stock
http://i257.photobucket.com/albums/h...mage0008-1.jpg

http://www.cnc4x4.org/

http://www.treadlightly.org/

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post #9 of 17 Old 02-28-2008, 09:36 PM
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Aside from the fact that these couplers are not meant to be subjected to the stress this use will put them under, and they will live a short life...have you ever tried to connect an air hose when the coupler is packed with dirt and mud? I don't see this being very easy to use after a day of wheeling, when it's time to reconnect.

'09 Rubicon
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post #10 of 17 Old 02-28-2008, 09:37 PM
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Hey Cha Cha , You did not answer my question on your last "new thread" that Arlo deleted for trying to sell them. Will these also add air in the tires ??? I ought to hook up my Paslode and ....ever see that movie Lethal Weapon ?
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post #11 of 17 Old 02-28-2008, 09:42 PM
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do a search on here or JU or one of these forums... someone made homemade discos and it was actually a safe design... if you want to go the cheapo route find that post

Matt
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post #12 of 17 Old 02-28-2008, 09:47 PM
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you have to give it to him though, although unsafe and possibly deadly, it was a pretty good idea.
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post #13 of 17 Old 02-28-2008, 09:51 PM
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$70 bucks and no safety issues.

Hunter

04 4.7 HO, limited

08 Z71 Suburban, front leveling kit with rear spacers. 285/65 18s Nitto TerraGrappler G2s

94 5.9 Laredo 6.5 RE lift with 35 Maxxis Bighorns
and 33 Bridgestone Duelers
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post #14 of 17 Old 02-28-2008, 09:54 PM Thread Starter
Cha Cha
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Thanks those are $70 more than the ones I built. Who are they made by?

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post #15 of 17 Old 02-28-2008, 09:58 PM Thread Starter
Cha Cha
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Since you guys like these so much i might as well start selling them, how does $115 a pop sound?

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