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911 SWAY BAR BRACKET UPGRADE
By Steve Grosekemper
As the evolution of the 911 progressed, the cars got both faster and heavier. This increase in power and weight demanded stiffer suspension systems to maintain the cars unique handling characteristics.
In the beginning, 911 rear sway bars were a mere 15mm in diameter. Soon they increased to 16mm and then to 18mm by 1974. During these upgrades, the sway bar bushing bracket remained the same size, so as the sway bars got larger the bushing thickness became thinner. In 1978 the bracket and bushing size increased to accommodate the growing sway bars sizes. This new bracket had a notch in the bottom to make room for the larger bushing. (Earlier versions were flat on the bottom, as seen in figure #1, bottom bracket)
While the sway bars and bushings increased in size and strength the sway bar brackets did not. The problem with this is the larger sway bars tend to flex the brackets causing them to tear into two pieces, not what any Porsche owner wants to have happen. After many bracket failures Porsche came out with a upgraded, reinforced bracket. (Top bracket, figure #1)
But what about those of us who have larger sway bars and no updated bracket? Or even worse, an early car with 19mm or 22mm bars? The answer is simple, just install a brace on your existing brackets so they can not flex and therefore will not break.
Aftermarket braces used to be available, but are now a thing of the past. What you can do is fabricate your own using the template shown in figure #2. The template is essentially the same brace that Porsche has welded onto their own updated bracket. Cut the brace out of .060" mild steel and bend a 90 degree angle at the dotted line. Then simply weld into place on the old bracket and you will have your very own factory simulated reinforced sway bar bracket!
If you happen to break an unreinforced bracket, replace it with an updated unit and install the brace on the other side of the car. After this is done you should not have any other problems with the bracket failure.
Good Luck
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