Record for shortest torsion bar life?

Pazuzu · 06:17 AM

2 months? If not, it is now!

Bought new rear 27mm solid SAW bars from our host and installed with new polybronze bushings and some Carrera sway bars on my slightly lightened SC. Ran as a daily driver, no track time for about 2 months.

They BOTH broke on me the other day while driving to work. Fortunately it was from a stop sign, and only a block from home, so I was able to limp it back.

These are suspect to me. These are the outside halves of both bars (don't get confused thinking they're part of the same bar).

1) They broke the EXACT same way. Long shear along the axial center line, dead flat surface inside that is black and symmetric, compared to the torn sections that show grey casting and torsional effects.

2) They broke in the SAME DIRECTION. Meaning, the L/R bars are tensioned opposite each other, so you would expect that one would "unpeel" clockwise and the other counterclockwise (as viewed, for example, from someone standing outside next to the tire). Instead, they BOTH unpeeled in the same direction. Did I not only get a bad batch, but also a mislabeled bar?

3) One shows that axial "surface" crack extending all of the way to the splines. In fact, it goes INTO the splines, to the end surface, through the stamped part numbers, and all of the way to the divot in the centerline. The ENTIRE bar seems to have an axial split. Once I get the inner half out I'll check more ion that.

So...anyone see a break like this before? anyone see it within 2 months of sane normal driving? Anyone think I can convince SAW to replace them as being a bad batch? Problem is, i got the last set of 27mm solid bars from our hosts, they're showing 3 weeks out now. do I suck it up and pay for 27mm hollow bars, or do I go with 28mm solids?

toddu · 08-10-2011, 06:50 AM

What size is your fronts? 21?

Todd

Pazuzu · 08-10-2011, 06:57 AM

21 fronts, also new with polybronze, Carrera front sway bar. done at the same time.

Pazuzu · 08-10-2011, 06:58 AM

Here's a old link from Widebody911 showing a similar axial crack:
Snapped Torsion Bar ??

toddu · 08-10-2011, 07:03 AM

I would call SW. They should replace them I would think, and they should be able to get them to you quicker than 3 weeks I would think.

How did you like the 27 for the short time? You might not like 28....

Todd

jmh61 · 08-10-2011, 07:03 AM

I have had the same bars on my car for over two years with no problems.

Based on your photos above that split looks like a manufacturing defect. The split would definitely reduce the torsional strength of the bar. With the split I'm not surprised they failed.

If I had the chance to do mine over again, I would put in hollow 28s or 29s. In progressing my suspension build it appears that shocks have a much greater affect on ride quality than TBs, so I think I could live with stiffer TBs. I would go hollow just to loose the weight on the back end. I'm getting more and more into AutoX and the more weight I can loose the better.

dad911 · 08-10-2011, 07:06 AM

I'm not an expert, but I would expect that linear crack would indicate a problem in manufacturing.

jmz · jmz's Garage

I'd return the defective bars, buy the Sanders Hollow bars and be done.

Pazuzu · 08-10-2011, 07:21 AM

Quote:

Originally Posted by toddu

I would call SW. They should replace them I would think, and they should be able to get them to you quicker than 3 weeks I would think.

How did you like the 27 for the short time? You might not like 28....

Todd

Stiff. I also upgraded to Bilstein HD/Sport combo front and rear.

I like the grip, but I'm very aware of how bad the Houston streets are now (and they've been getting worse with this drought). I do think that with all of the upgrades, I'm near the limit of what I want to deal with as a DD and rarely trackday car.

hcoles · 08-10-2011, 07:44 AM

If I was Wayne I would ask for a root cause analysis and action plan. If the process is not fixed it will happen again assuming the application is per what is expected. Until this is explained I would not recommend these bars. Please post if you get a story from our host or SAW.

HawgRyder · HawgRyder's Garage

How do you get the inside piece out?
It just occurred to me that it ends up way inside the hole.
Bob

hcoles · 08-10-2011, 08:24 AM

Quote:

Originally Posted by HawgRyder

How do you get the inside piece out?
It just occurred to me that it ends up way inside the hole.
Bob

how about a long sleeve with the ID just over the OD of the bar and JBWeld? Good question.

Pazuzu · 08-10-2011, 08:27 AM

Haven't yet!

I was freaking ecstatic when I found that, yes, my two basically brand new, oversized torsion bars did actually break simultaneously that I didn't go digging around yet for the inside halves (that's this weekend's project...).

See, limping home I said to myself "self, there's no way that you just had both brand new bars snap. You did not go rally racing, did not scratch them before installing, did not drop them in the fires of a volcano, nothing. They couldn't BOTH have broken after 2 month. Therefore self, what MUST have happened is the inner spline sleeve in the torsion bar tube must have come loose/broken/rusted away."

So, finding out that it WAS just the bars made me strangely happy, because the NEXT option was too much to bear

I expect lots of swearing and spitting to get the inner halves out, but I will.

dad911 · 08-10-2011, 08:34 AM

I may be wrong, but I think you can push them through???? I think the center spline goes straight through.

Pazuzu · 08-10-2011, 08:35 AM

Yes, you can push them through from the other side. However, if they have bent when breaking, then it becomes much harder.

The pieces that came out where still arrow straight, so I'm *hoping* that the inside pieces will not be an issue.

Also, since they were well greased and only in for 2 months, they should come loose from the splines very easily.

Tippy · 08-10-2011, 08:40 AM

Damn! Time for coilovers!

That is crazy.

Pazuzu · 08-10-2011, 08:50 AM

Quote:

Originally Posted by Tippy

Damn! Time for coilovers!

That is crazy.

Don't you even say that!!

If I hadn't spent so much on upgrading the stock suspension, I might have considered it...

I'm just going to roll with the idea that my car is so massively bad a$$ and so full of Gut Wrenching Power that it can snap torsion bars at will.

I think I'll go slam a beer and start a fight now...

skunked · skunked's Garage

wow.

Hopefully they get you some replacements and an explanation quick.

JerryL · 08-10-2011, 09:17 AM

If I was SW I would get you some bars quick WHILE I am contemplating how many others were in that batch of material and or batch heat treating process
And I hate to say it I would look else where and buck up for the hollow bars from another manufacturer if that is what is available for imediate delivery.
And as said earlier SW should provide Both Customers (you and P.Parts) a root cause, not just give a replacement. There is WAY too much in a safety relationship to your car / life to settle for less.

Just my $.02

Regards

Pazuzu · 08-10-2011, 09:26 AM

I do still have my stocker t-bars on the shelf, they were clean and 99% rust free, I will put them in this weekend since this is my daily driver. Gotta get it back up and running, the bus sucks.
There doesn't appear to be any damage to the spring plates, bushing, etc. I *presume* there's no damage to the inner splines.