Lots of interesting comments here. I think I stated in my first post that this probably doesn't make any real sense financially, since good used anti-roll bars can probably be had for next to nothing, and there would be no way to recoup the initial investment of fabricating your own set unless you planned to sell a few (a bunch
) of them.
I also agree with the comments made about heat treating, spring rate calculations, etc. That would be one of the first things one would do when researching this idea,
after posting on Pelican, of course
Most of us don't have an oven suitable for heat treating a bar once it was bent, but there are places that will do this for you. ($$$) Most of us don't have a means of bending 3/4" 4140, and, quite frankly, I'm not sure if I would trust a tubing bender for the job. But it can be done. (more $$$)
Does it make sense? Probably not. Look at what aftermarket bars go for from companies such as Tarrett, Smart, Welt, and Elephant. That should give one an idea of the $ investment, research, and testing that goes into making a quality product.
I happen to have access to some pretty nice manufacturing equipment, and I know how to use it, or know how to find someone who knows more than me to do it for me. That's why I encouraged Jason to give it a go, since I assumed he was going to do enough research to, at the very least, not hurt himself. Will he end up with a quality product that works and last more than one drive? Who knows, probably not. But he might learn something, and have fun doing it.
And, I think that's one of the primary reasons most of us here on Pelican are DIYers.
Jim