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Old 11-25-2024, 11:50 AM   #127
DocWalt
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Designed some new rear swaybar mounts to get rid of the ridiculous stock rear swaybar subframe and optimize the rear swaybar geometry. My printer ran out of filament, but the parts were still usable for test fitment at least. I'll get them done in aluminum now

Silly stock rear swaybar subframe and its mounting location:



My design:










I also swapped to 3.73 gearing from the stock 4.10, I was tired of ~59 mph in 2nd being my top speed. I was abusing the rev limiter a LOT this year. I bought a used 2014 IS250 diff and swapped my OS Giken into. The Lexus diff appeared to have never been serviced, it smelled AWFUL and was full of sludge. Truly so bad smelling that while I was working on it in the garage, my wife came outside to ask me a question about dinner and she stopped dead in her tracks to ask what the smell was, haha. Gearing is much better now! ~65 mph in 2nd and it's a more calm cruise on the highway. There's definitely a bit of loss of acceleration but honestly it feels totally fine. I really wish Subaru had used 3.91 gearing in the 2022+ cars, the automatic got 3.91s but the manual was 4.10s like early first gen twins.

The Lexus diff when I opened it:



Wiped off one section of the diff cover, you can see how gross it was with a line of sludge showing the fill level.



Much better!



New diff assembled, backlash and pattern checked out perfectly. I love how well made the OS Gikens are, I've not needed to adjust shims once on any of them, they just drop in perfectly like an OEM diff.

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Old 11-25-2024, 01:32 PM   #128
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Originally Posted by DocWalt View Post
Designed some new rear swaybar mounts to get rid of the ridiculous stock rear swaybar subframe and optimize the rear swaybar geometry. My printer ran out of filament, but the parts were still usable for test fitment at least. I'll get them done in aluminum now


I like it. Is this last pic at ride height or in the air? How long are your endlinks? Is the middle setting on your rear bar about where the OEM bar hole is located?

I'd been toying with ideas for a new swaybar mount for 1st gen and GR86 but it's not easy to do it the way I want to without cutting anything. The BRZ mount is much easier to replace.

- Andrew
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Old 11-25-2024, 03:09 PM   #129
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I like it. Is this last pic at ride height or in the air? How long are your endlinks? Is the middle setting on your rear bar about where the OEM bar hole is located?

I'd been toying with ideas for a new swaybar mount for 1st gen and GR86 but it's not easy to do it the way I want to without cutting anything. The BRZ mount is much easier to replace.

- Andrew

That was in the air, I've tweaked the design to move the bar up a little more and get the bar a bit more level.

The middle hole is where the OEM bar lands, I did test that but neglected to take pics (was too busy dropping the diff on my face )


End links are custom ones I made out of McMaster parts, I didn't measure them, but they're about as short as you can make without getting custom heims/rod ends or modifying stuff.


The Revolution rear swaybar mount for first gens/GR86 is a pretty decent bolt on solution, but it could definitely be tweaked a bit to be more ideal. https://www.rhdjapan.com/revolution-...-gr86-zn8.html
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Old 11-25-2024, 08:34 PM   #130
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Wow nice work Ken. Had no idea this was even a thing
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Old 11-26-2024, 03:12 PM   #131
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Nice driving! Car looks like a blast and sounds great.
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2022 BRZ Build
2013 FR-S Build
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Old 12-09-2024, 05:13 PM   #132
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This is definitely the coolest car project I've done yet, IMO. I designed new rear swaybar mounts to correct the rear swaybar geometry when lowered and stiffen the mounts. I sent the design off to be 3D printed in aluminum and they arrived today. The whole process was great, the printer communicated with me the whole time and confirmed some aspects of my design. For example, they 3D printed the threads into the mount so I didn't have to tap the holes. So cool!





The design ended up being perfect and everything went together smoothly.



This is the stock geometry, you can see how the swaybar isn't perpendicular to the end link or the ground but it's also not centered on the control arm so it can torque the arm.



My design fixes that

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Old 12-10-2024, 02:15 PM   #133
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Amazing work !
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Old 12-19-2024, 01:44 PM   #134
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Installed underglow, silly but fun.

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Old 12-19-2024, 07:37 PM   #135
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Do you have any driving impressions on the rear sway bar relocation? Are you anticipating more predictability and less of a chance of binding?
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Old 12-19-2024, 09:19 PM   #136
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Do you have any driving impressions on the rear sway bar relocation? Are you anticipating more predictability and less of a chance of binding?

It feels a bit softer/more compliant on the street, which is interesting. A little more understeer maybe?

I'm expecting more predictability as the big benefit.
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