Re: Home Made Sway Bar Disconnects.
Whew, good, I found it! God bless "search" and "copy". Here's something I posted a while back:
With only 1 3/4" lift shackles our links had to be lengthened. If I recall, the bottom bolts came out pretty easily. The easiest way to get the top out is to remove the whole sway bar, put the nut loosely on the end of the top link bolt to protect the threads, sit the nut against a board or something, and whack the sway bar with a hammer. Comes right out. A cheap way (about $20 or less) to make longer and disconnectable links is to cut the old ones so there is about 3/4" of rod on each end. Get four 3/8" "coupling nuts" which are about 1 3/4" long. Run a die on the 3/4" piece of rod you left on your link ends to thread it to match the nuts. Screw the nuts onto the link ends. Next get some 3/4" rigid electric conduit nipples. They come in different lengths so figure out what length you need. You may be able to get two out of one nipple. The nipples fit over the coupling nuts without much slop. Saw or use a pipe cutter to cut the nipples to the lengths you need. (I cut the threaded ends off for appearance sake.) Put the nipple over the nuts and drill a hole thru the whole works on each end to fit a latch pin. Line the hole up so it goes thru the half of the nut that the old link isn't into. If you ever change lift, just buy some new nipples for a couple bucks each and make them longer. You have to get the "rigid" conduit at an electric supply house and we found latch pins just like they use on the $100 sway bar disconnects at the local RV and Camping supply store.
We did the nuts, because the stock disconnect is only 3/8" diameter and if you'd drill a hole thru it for any decent sized latch pin, there wouldn't be much left. They have been holding up just fine. In fact we put lift springs on and had to lengthen even more but it was a breeze. Just picked up more nipples for a couple bucks each, set the old ones in a vise over top the new ones as a guide, and ran the drill thru. Saved the old ones...who knows, might go lower some day. Oh yeah, the nipples come galvanized so no finishing is required.