progress anti-sway bar bump noise fix
 

Sooo..

I have progrees anti-sway bars.

For a while I had been experiencing a strang bump noise. It felt like some one was tapping the front under floor panel with a hammer when I would go over bumps.

Everything in the suspension was tight. I checked it over 3 times. By this I mean I took off the front under panel and tightend every bolt and nut on the car. This also included the entire front suspension.

1. I first thought I had a power steering rack issue because the car wandered a bit and I could tell on high speed turns, (100mph plus) that the wheel would move off center a tad bit.

I later realized I just need an alignment and some new tires for the tracking issues. The car follows groves easily. But it really does not bother me for canyon driving. But why did the steering wheel move?

2. I then looked into my motor mounts. I have a very small gap in between my bump stops. I thought that maybe my bump stops had been hitting from weakining motor mounts.

Motor mounts checked out fine.

3. Looked for any signs of unusual play and gaps and this is what I found.

I was pretty confident by now so I grabbed my camera so I could take before and after pictures.

The pictures below shows gaps forming where the anti-sway goes through the bushing that is secured by the provided anti-sway bar bracket. If you look closely you can see where the metal is lifting underneath the top bolt.

This play will allow the sway bar to move enough in a lateral direction under hard cornering to cause the issue stated in number 1 problem. "why did my steering wheel move a tiny bit while high speed corner?" It moved because suddenly there was more preasure on one side as opposed to the other. I was almost not noticable, but I felt it in the steering wheel.

You can also see that the bracket can not be centered due to the top nut. That is why the bolts are at the top of the slots.

In the third pic from the left, ( play 3 ), you can see the bracket bending and lifting away. AND you can see some STRESS CRACKS!!!

I took off the brackets and saw the deformation. I re-bent the brackets to be straight along with making the ends closer together. I made them close enough to where as I needed a hammer to tap them back on over the bushings.

You can see the warped bracket on the left and the fixed on on the right.

After fixing the brackets, I flipped both sides upside down. I wanted the un-bent side of the bracket up top since that is where most of the preasure will be. That is why you see the older marks.

So you can see that there is no longer a gap. I even added lock washers and a larger washer on top to reduce the area that can bend.

The photo on the left shows how the larger washers makes the area less able to bend.

The noise is gone. Everything is back to normal, the car feels more stable on high speed corners.

This my not be the same problem for everyone else. But it is still a problem for some.

I hope the write helps.

Ben

IMO this was caused by not centering the the bracket on the mounting nuts, in the before photo you can see that it's not centered which put a big area between the one hold-down nut and the bushing, I had the same thing happen with an aftermarket Energy Suspension bracket on a softer bar

adding the washers for more support is a good idea

they must have changed the design, I don't recall my brackets having slots, but this was several years ago

Yes Team, that is the issue. But you see the bolt on top that stops the bracket from being centered in the first place.

I will have to make another one out of stronger metal, that is also shorter so that it can be centered.

Great sway bar ruined by crappy brackets.

this is interesting,

as i have teams old bars, but have never had an issue.

one side had a slot. i will have to get under the car a look.

but for me no noise safe and sound..

beers :beer:

no, the Energy Suspension brackets do the same thing

you simply let the bracket overlay the bolt that holds the ABS cable hold-down.

When you center and bolt the bracket down the small amount of bracket over that bolt will bend as the top bracket bolt is cinched down

with the ES brackets I now cut that piece off with a bandsaw, but I did it like this for years without an issue, I'm sure it's posted on here somewhere

the brackets aren't crappy, they're just a universal type intended to fit a wide variety of applications, not just the RX-8, the Progress bars aren't high dollar, they could make dedicated brackets but would have to charge more since the production runs for them would be small

OK I'll meet you have way on this issues. The metal is low grade because it bent more easily then it should have. I could overlay the other bolt or simple bend that part up. But I should not have to as a customer. I also wanted to add the after I straighted the bent part on the bracket, I now have a nice stress crack.


But still, the sway bar increased the diameter of the bracket from movement.

Anyways, Thanks for everyones input. I see no fault of mine on installation. It is just an issue like any other issue when you start changing stuff to aftermarket stuff.

I love these bars, bracket was just an annoying issue.

I wonder if they made these brackets on a car without DSC. That bolt on top with that wire is part of the DSC system. Their would be no issue for people without DSC.

Or maybe I'm wrong.

Team, maybe the supplier is different from the ones you have. I mean seriously, These brackets really bent easy when I went to repair them. The metal is really low grade.

I would agree with this, its minor but I haven't had problems with this and I made sure to center the bolt on the "slot".

I'm always impressed to see how a really tiny abnormality like this can cause such an obvious noise/problem...

I agree too, obviously that IS why it bent.

I really hope nobody thinks that I am arguing that.

It is just that a better, more specific bracket could have been supplied.

I'm going to make other brackets because I want a stronger bracket and make it right so that I will not have to block access to another bolt.

Also, I know that there are others out there who will want a specific made bracket for the 8. I know some other brand anti-sway bars may have a difference in diameter though. Sooo.. what I would like to do might not help those guys.

Anyways.

Since I have the resources, I'll make some affordable brackets.

I'll make mine, if you guys like em, I'll make some for other people too.

The cost to make the bracket (materials), shipping, plus 5 bucks. All that should be less then 20 bucks. So what do you guys think, 20 bucks shipped for some beefier brackets. Made right, not slots, no over lapping bolts. Id prefer to use stainless steel, but that'll be 30 per bracket.

I just really really don't like it when metal bends. A strong bracket would not have bent, even if it was off center.

Ben

My car is a 2005 Base, no DSC, it is for the ABS cable, all RX-8s have ABS

Racing Beat uses a dedicated bracket (no slots) on their front RX-8 bar that uses the same bushing. They only advertise the bushings for replacement sale, but you might call to ask if the brackets are available too.

Otherwise you can but the Energy SUspension bushing/bracket assemblies, but they're a universal fit with slots and the bracket will overlay the ABS cable hold-down bolt head when centered properly

Thanks for the clarification. Anyways, The older brackets are 12 gauge metal, the ones I had bent too easily IMHO,. My new brackets will be 10 gauge and mild steel. Thanks for the feedback Team.

dude same thing happened to mine! i just ordered one bracket cause mine actually BROKE!lol if you do decide to make some beefier brackets im in!

I am already making them. I'll post picks once mine are done so you guys can see if you like them. I'll compare the brackets side by side too.

I had them done for a week now. The fabricator did a pretty good job. I installed my new brackets and no more bumping noise. These are also centered and do not have to be placed over any other bolts. I can offer these to other people, but they will be SS only. Mine are mild steel for the prototypes.

Ben

look very good ben.. :)

beers :beer:

Thanks Swoope, if anyone else wants some. SS brackets will be 55 shipped in the lower 48 states and 65 shipped to everywhere else. I'm not making money, well enough to pay for my gas and bridge toll to the fabricator..lol, I want to just spread some love.

Also, I noticed that the car turns in a bit better because the sway bar is bolted a little higher..(centered). Before with the sway bar bolted lower, it felt different. I have to re-learn the car.

I would like to suggest a cheaper fix

make square washers with a hole drilled in them such that when you put them on between the bracket and the nut they are up tight on the bushing side of the bracket and center it properly. IMO the extra stiffness on the bracket's mounting surface and centering will solve the problem completely. The mounting studs are long enough that that the square washers can be fairly thick and it will cost a whole lot less than $55 :uhh:

Thanks for making this thread. Have the same problem and couldn't find what was wrong. Re-tightened the entire suspension as well.

I agree with you team on the cheaper fix. I just made mine because I wanted a one piece solid bracket. Plus the SS one will not fail.

It will be upto the individual on which route they take. Both ways will work.

Progress and Racing Beat front anti-sway bars are 32 mm. So these brackets should be good for these two and what ever else sway bars are out there that are 32mm.

SS bracket pictures

An update for everyone.

The SS brackets I made for me and another member sheared at the bend. The new brackets I have available are only the standard steel but they are thicker and are reinforced with a weld on the top of the bend. I have sent this out to replace the SS ones I sold and these new ones are working fine.

Ben