Pelican Parts Forums - Swayaway adjustable spring plates

I know that this has been mentioned before on previous posts but I feel that it is worth revisiting. I have recently gone down the well worn track of installing the usual suspension upgrades, thicker torsion bars, Elephant Racing bushes, bump steer kit, free front end kit and the Sway Away adjustable spring plates. Nothing new here you say and I am of course inclined to agree with you.
The thing that amazed me though was the fact that the spring plates were such a lousy fit. Yet there is little or no concern that I can see apart form one previous poster.
When installing the new spring plates I noticed that the male splines on the torsion bar only just mates up to the female splines of the spring plate. In fact only about 12mm or so in. When there is approx. 32mm spline available. See [image 1] Noticing this I quickly measured everything making sure everything was located correctly and were the right lengths. Nothing was found amiss So a check of the PP forum was carried out . Yes, there was another post from a member with concerns but I feel that having now addressed this issue I would submit a post myself.
It was evident that what ever I did the torsion bars were just too short for the space allocated to them . If I wanted to have the correct depth of spline match I only had two choices. Stretch the TB's or reposition the spring plates on the splined hub. I chose the latter. Others have mentioned the placing of spacers but this seemed like a bit of a half hearted effort and does not give the correct spline engagement just spreads it out a little so they are a little more equal on the inner and outer splines.
This of course is not going to be in everyone's reach as it requires the use of a lathe and competent rewelding. [I am a lousy welder but my mates not] Loosely what is required is careful removal by lathe of the weld between the plate and the splined hub. The splined hub is then turned down to enable more spline engagement. Once turned, the plate has to be rewelded to the splined hub. If you have done correctly you will have result that looks more or less like this[See image#2] Much better than image #1.
I also turned up some end covers in alluminium while I was about it to finish off the job.[see image #3] Wasn't happy with just the red plastic cups that come as standard.
Now, what I don't understand is how these things can be fitted year after by people, some who should know better with such poor spline engagement without concern. Obviously there doesn't appear to be major issues or the web would be full of posts. Why hasn't Sway Away corrected the situation or is it just convenient for them as it fts in with other machining requirements with in their organisation.
Anyway there you have it that's what I did others may not be concerned.
R. Dave

http://forums.pelicanparts.com/uploa...1222661847.jpg
http://forums.pelicanparts.com/uploa...1222661947.jpg