I'm looking to try and produce some sway bars. I have a little bit of fabrication skill and a little more knowledge on suspension tuning. I think I'm looking at Chromoly and hollow if possible.

I apologize for the newbie sounding question.

 

Good question. Interested to see what, if anything, has been done.

 

you can make them any number of ways. just use your imagination a little.
if you dont have access to a bender then you could make one by welding a splined sleeve over the ends and adding arms that have the female spline on them.

 

There are a number of universal kits. Summit or Jegs will have them as well as any circle track supplier. You should be able to buy different length arms, shafts, hollow or solid, carrier bearings, etc.

 

We manufacture a number of private label sway bars. The typical sway bar is made from 4130 normalized solid bar in 7/8, 1", or 1.25". It's very strong, very resiliant material and it's bent on radiuses approaching 1*diameter, so it requires a very large cnc bender to form them accurately. The bars are then placed into a fixture and the tabs and mounts are welded onto them. Then we torch stress relieve the weld joints and send them to powder coating.

 

search the welding fab forums a little more. we ha da thread about this no more than 2 months ago. it should have what you need.