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Re: Reinforcing Sway Bar Mounts (archive)

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Posted by RA/Bob G. on January 09, 2001 at 04:15:07:

In Reply to: Reinforcing Sway Bar Mounts posted by Bob on January 09, 2001 at 02:01:16:

I hear a lot about this, and though I've had no problems with the 25/19 bars on my 535is (yet) it does concern me.

How did you reinforce them?

Did you add extra welds on the existing mounts where they attach to the frame, or did you mig a 90 degree extension onto the existing tab (so it attaches by inserting it into the slot and then rotating it 90 deg over the swar bar bushing and onto the pad) so it cannot pull out?

I'm not sure whether the problem is the whole pad pulling free of the frame, or the tabs just pulling free of the slots in the pad, or both.


I am preparing to install a set of used sway bars 22/16 on my 535is. Which of the three holes will likely work the best. I will be using the car as a daily driver and for driving schools. Only other suspension mod is a set of RD springs and a set of 225/50/15 R1s for the track.

Jim's suggestion is a good one.HOWEVER,running a 535is with stock brakes added to stiffer swaybars,and the R1's,there's a 50% chance of warping the rotors before driver's school is finished. Ask me how I know...

1. try to add ducting to the brakes from the small oval opening below the foglites,& remove the front backing plates for cooling. or...
2.gas-slot the rotors or use cross-drilled,adding a track pad compound. or...
3.upgrade to the 7 series front brakes.

Then,you will probably want to weld tabs to reinforce the center brackets for the swaybars.BMW left a bolt on one side,but only a tab on the other,which often pulls right out,just in the middle of school. HAH! Ask me how I know that one too.
And make sure the 15" wheels you use have a design that allows ALOT of airflow.Old 750 rims,or the 20-spoke "bottle cap" rims,don't cool well enough at a long track if you drive hard,unless you add one of the precautions I mentioned above.
Now you can enjoy the driver's school weekend.

BOB....the biggest problem is the tabs ripping out...we welded in a matchbook size reinforcing plate there; for most people that's quite enough.
MY '85 "trick" car was used with the 3.73lsd,the 7 series brakes(gas slotted in a race shop,and running hand-made carbon/kevlar pads),LARGE bars,lowered 2",Eibach's,Koni's,custom 6800rpm chip,adjustable fuel press.regulator,Schroth harnesses,16x7.5 Hartge's with 205/55/16 race compound,a few tricks we'll leave out,and would out-brake all but race cars and the e36 M3's,and out corner 85% of everything it saw,period.And this was in '89/'90,before most were aware that alot of these changes were possible....drove the e28 M5's nuts.THAT car needed plates welded in 20 places to keep it together.

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