Broken Stud - Rear Sway Bar Mount

The hockey pucks work better if you bore a 1-1/2" hole through them but you need more then one since the split easily. Maybe they saw an old girl friend sitting in the stands and want to avoid her?

You want to use a bolt marked 10.6. I personally think that the original size of the studs was too small to begin with. From experience, you do not want one of the studs on the anti-sway bars breaking on you while you are "on it".

You will likely spin the car out suddenly.

I'm always cautious of Canadian women. They are different then Americans and take pleasure in breaking off studs.

I went to my bolt store to get a M8 10.9 bolt and the longest full thread they had was 40mm.  The stud I made is 42mm.  I will have to look further for a 45mm bolt.

McMaster-Carr has 50mm studs in 10.9 and 12.9. 

Wouldn't this style of stud be appropriate for this application?

They are designed for this sort of installation with two features, they bottom out against the full section shank and are cut with a tighter fitting interference thread so they will stay put and won't wobble.

Too much unthreaded area, will not clamp thin bracket.

The weakest part is the part you threaded into… My humble opinion, a M8 grade 8.8 stud, used on, as previously mentioned, drilled out, and re-threatened original bolt hole , using the head of the left over bolt to be threaded as well should be sufficient (and the weakest link before the grade 8 bolt snaps) …  and use the original rubber swaybar  bushings versus the Polyurethane bushings which are not very forgiving!!

If you wanted to be really strong, you have to cut the crossmember open or make a plate sitting on top of the crossmember and weld it on.

would be a nice project…

thinking out loud:

drill a hole where the bolt supposed to be the size of the bolt head to be used, stick the bolted in the hole welded in place then make a plate with two holes where the threats only protrude and weld that plate onto the crossmember.

there are many other ways to do it and make it stronger…