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I received my Z06 swaybars from Fred Beans a couple of weeks ago. I was considering dressing them up some before I install them. I have a couple of questions.
1. Will powder coating hold up to the stresses on a sway bar?
2. What color have people seen that looks good? My car is a 2004 machine silver vert. I was thinking red for the bars.
3. Best way to deal with the witness marks on the bars for centering in the bushings. Thought I might trace the basic bar shape on cardboard and add the marks. Then when I install add tape back for the alignment. Or just measure from the end of the bars...
4. Skip the coating and just get the bars on drive the buhjeeezus out of em!
Painted mine red (Ford Red to be exact). Got the paint from Wal-mart, I rough sanded the bars 1st then applied 3 coats. I did the front bar also. I tapped the ends and the marks (reference) where the bushings go
3. Best way to deal with the witness marks on the bars for centering in the bushings. Thought I might trace the basic bar shape on cardboard and add the marks. Then when I install add tape back for the alignment. Or just measure from the end of the bars...
Don't worry about the witness marks. You can't, and shouldn't, do much about side-to-side alignment. In many ways, it is self aligning, but there will always be some play. One of the big auto makers published a paper about trying to lock the bar from side motions, but they found the extra stresses caused by the locking devices to be unacceptable. If you'd like, I can email the paper to you...just let me know.
First, I think its a waste of time doing anything to the front bar as its nearly impossible to see it. Just clean and wax it up a little.
Second, powdercoating is probably a waste of time and money.
You can get a great finish on the rear bar if you want by sanding it some then applying about 5-10 light coats of Sunset Red spray paint from Home Depot ($3.97). More coats if you want
Apply each coat about 1- 2 minutes apart. Let it dry 24 hrs and you're good to go.
I taped over the bushing marker paint and only painted inside the markers (you can't see the rest of the bar anyway) then hung the bar using a bungie from the end of an open garage door. Worked nice 'cuz you could easily spray all of it while moving around the bar.
BTW, the paint/coating that comes on the bar is quite thick. It may already be powdercoated.