Description

Uploading this to address 2 issues with the status quo, affecting any 924 or 944 with the steel front control arm design. Note that this is discussing the outer bushing, at the control arm. Stock rubber bushing will only work with the smaller sway bar diameters. The ends (that go into these bushings) are thicker on 25.5mm sway bars and higher. Therefore if you wish to upgrade to a larger front sway bar, the main option is to drill out the rubber by a few millimeters. To my knowledge, the only aftermarket direct replacement option is offered by PowerFlex, part number PFF57-307. However there have been fitment issues reported as recently as 2019, some chamfering may be needed. The PFF57-207 version is sized incorrectly and is to be avoided. Unfortunately for both of these parts, the inner bore is sized for the smaller sizes of sway bars and again requires drilling, per the above. Note that Lindsey Racing sells a mount which replaces the factory design altogether, part number LRA-ESBM, and enables you to use the 85.5+ bushing design. At the time of writing this kit costs 160 USD.   This design attempts to solve for these shortcomings: Sized for larger sway bar ends: ~19mm bore I am attaching the SolidWorks file if you wish to reduce the bore diameter to fit the smaller sizes. I do not have this measurement on hand, it is very slightly smaller. Greasable design - there is a provision for a zerk, and internal grease channels. If you do not wish to drill and tap the drop links, this shouldn't be a problem to leave as-is. Slit in the base to facilitate installation. It is tight, but will go in.   For those wondering about the durability of a 3D printed bushing, this is admittedly not well studied. TPU printed at 100% infill is incredibly robust and virtually isotropic… cutting one open reveals no evidence of layer lines or an obvious ‘strong’ or ‘weak’ load axis bias. I am running these on one of my cars and will report back if I ever have issues. These are (gene