yes the bars will fit all chassis
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Sway bars/Anti roll bars remanufactured
- Thread starter T0Pnotch55
- Start date
Hi everyone, update, i received the sway bar prototype today, they forgot to add the small notch on the rear bar for SLS clearance, i already told them about it and they will fix it, but overall the bars look great, pretty heavy bars, especially the front one 
but looks good, me personally i like it, i think it came out great, i will check for proper fitment on the car and if everything checks out will go into production, i apologize it takes so long
ill some videos later
but looks good, me personally i like it, i think it came out great, i will check for proper fitment on the car and if everything checks out will go into production, i apologize it takes so longill some videos later
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here are some videos
more pictures, the ends of the rear bar are slightly thicker, i don’t think it will be a problem but i will confirm that after i mount the bars to the car, the manufacturer told me that because the new bar is thicker the press can’t squish it more that it is now
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Great work! Excited to get a set of these. My M275 swap is on schedule to be complete by the end of October, so this is perfect timing.
FYI, I don't mind the ends being thicker, in case that's the way they have to be made. Also, my car does not have the SLS suspension, in case you need to move this set.
FYI, I don't mind the ends being thicker, in case that's the way they have to be made. Also, my car does not have the SLS suspension, in case you need to move this set.
good luck on the project, i spoke with the manufacturer and i am waiting for a respond from them, they might need this one back or they will send another one, ill know this by the end of the week
I know it's late now, but why can't they just machine the tapered ends on the front swaybar to match the stock design??
On all attempts of reproduction I've seen so far, the production units complains about doing that - despite that the swaybar ends are machined in raw material condition i.e. as straight rods, before the bending and heat treatment process takes place. That additional machining would probably take 2 minutes at max per end to achieve a 100% identical shape as the stock swaybars.
Do they provide any test certificate on this?
On all attempts of reproduction I've seen so far, the production units complains about doing that - despite that the swaybar ends are machined in raw material condition i.e. as straight rods, before the bending and heat treatment process takes place. That additional machining would probably take 2 minutes at max per end to achieve a 100% identical shape as the stock swaybars.
Do they provide any test certificate on this?
hi, i copied the Renntech design not the E60 AMG design, i provided them with my design, i told them to make it like that, may i ask what is your concern about it being like this?
The Renntech design has higher stiffness due to the 32 mm overall dia. Additionally it is a stress concentration in the abrupt transition from 32 to 22 mm, although I have never heard of anyone broken at that point. The stock E60 swaybar has different characteristics, it is softer due to the minus 2 mm dia, and has much more flex at the longer 22 mm end sections. So for me only the stock size & design counts.
Additionally, it's a bit annoying that the fabricators drives the price up with mystical talk about that longer 22 mm section. It is some minutes more machining and a slightly different bending process and fixtures. The final heat treatment is the same. Just look it up on YouTube, this is not rocket science.
i am aware that its not a very complicated process in making the bars, before i made a decision to make a small batch of sway bars i made the post and i welcomed all the input from everyone because i wanted to make sure people will be satisfied, very few people chiped inn with comments, i apologize if this design doesn’t work for you, considering that currently there is nobody making sway bars for this platform i wanted to make some for myself and for some other people who would be interested, the specs on these bars is 30mm front with renntech design and 20mm rear pretty simple, it probably be slightly stiffer than the oem E60 front barr due to having the tapering closer to the end of the bar, but i don’t think it should perform just fine
@T0Pnotch55 - please believe me, you have absolutely no reason for excuses. Hey, you are the first person here making this come through - you deserve all creds for doing that! You have shared the progress along the way and you haven't asked for anything to cover the cost, so this is just great for all here!
That I have other technical thoughts around this goes on me, so thank you for taking the initiative!
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hi everyone, small update, testfiting the front sway bar went very well, it was a little bit of work but i got it bolted in utilizing the stock brackets, driving the car i can easily tell that there is a significant difference, the ride quality is still comfortable, i think its the right amount of stiffness, i personally like how it turned out, i hope everyone will be satisfied as well. I was not able to test fit the rear bar yet, the stock bravkets are to small to accommodate the bigger bushings, i am trying to find a solution maybe an off the shelf bravket that would work or a custom one.
test fitting was done on 1993 500E
test fitting was done on 1993 500E
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here are some pictures of the rear sway bar end links, because the new bar has the mounting ends slightly thicker i checked if there is not an issue to mount the end links, there is still enough bolt thread left to mount it, the end links are from the W124 Wagon, a nice upgrade over the plastic ones
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After talking with T0Pnotch55 about rear bushing and bracket options, I came back and reviewed this discussion and thought I'd add my 3 cents. It was going to be 2 cents, but I got carried away.
I think the bushing Dave mentions here is the W210 E55 rear bushing. Some interchanges show that it fits 94-97 E420, but I believe that is an error. The overall dimension of the bushing is too big to fit the W124 bracket, and there definitely can't be a bigger W124 bracket because the standard bracket is as large as possible given the bolt hole spacing in the chassis.
I am using these bushings in my 400E which has an E55 rear bar. I had to make a custom bushing mount solution in order to use these bushings (and also to solve some unrelated clearance issues).
I do not believe there is any bolt in solution for a 20mm bushing in a W124. The simplest option would be to use an 18mm bushing, which should work with a little extra assembly force.
Another option would be to modify the W124 chassis to accept a larger bushing mount bracket. This would involve a lot of careful work, and of course means cutting/welding/drilling the W124 body, which most people probably don't want to do.
The last option would be to custom machine an adapter to bolt the larger bracket into the W124. That custom machining option is probably outside the scope of most DIYers though.
Ok, hold up. I have news.
I dug through my crap. It pays to be a high-functioning hoarder sometimes. I found an old 20mm W210 bushing, as well as a W124 bushing and bracket. The W210 20mm bushing won't fit the W124 bracket, but I think it would be possible to use the W210 bushing with a W202/W210 bracket, or just a custom one. My concern was the bolt hole spacing, but I just checked, and I think it will actually be fine.
I think you could take the 2023260226 bracket, and just slot the holes in order to fit it to the W124 chassis. You might have to replace the standard hex bolts with socket head cap screws and washers, but one way or another it can be made to work. Slotting could be done with a die grinder and a carbide burr. Or better yet with a milling machine. Getting a bunch of those brackets and batch machining could be a hassle, but if each buyer sourced their own from their dealer or a junk yard, and slotted their own, it could work.
For a custom part, I'd probably do something like having a bunch of blanks laser cut by someone like Send Cut Send, and then make a set of dies I could use to stamp the blanks to the correct form. I might even have them zinc plated afterwards for a factory appearance.
I dug through my crap. It pays to be a high-functioning hoarder sometimes. I found an old 20mm W210 bushing, as well as a W124 bushing and bracket. The W210 20mm bushing won't fit the W124 bracket, but I think it would be possible to use the W210 bushing with a W202/W210 bracket, or just a custom one. My concern was the bolt hole spacing, but I just checked, and I think it will actually be fine.
I think you could take the 2023260226 bracket, and just slot the holes in order to fit it to the W124 chassis. You might have to replace the standard hex bolts with socket head cap screws and washers, but one way or another it can be made to work. Slotting could be done with a die grinder and a carbide burr. Or better yet with a milling machine. Getting a bunch of those brackets and batch machining could be a hassle, but if each buyer sourced their own from their dealer or a junk yard, and slotted their own, it could work.
For a custom part, I'd probably do something like having a bunch of blanks laser cut by someone like Send Cut Send, and then make a set of dies I could use to stamp the blanks to the correct form. I might even have them zinc plated afterwards for a factory appearance.
I'm going to run down to the junk yard and grab one of those brackets to confirm it'll fit.
thats what i was thinking to do, i ordered a set of brackets already and ill confirm this week if it works, in my head it works i think its more than 50% that it will work
EPC shows A2103260026 for the E55 bracket, unique to that chassis in USA. This bracket is an aluminum block, not stamped steel but of course it's NLA. I have a pair of them somewhere but somehow forgot to take photos for my website. 
A2023260226 is for most all other 202, 208, 210. This is stamped steel. I also have a pair of these somewhere... again, forgot photos. Still available new, but spendy at $20 MSRP each. Should be plenty in junkyards.
I need to dig up both pairs and document them on my website.
I still think using the stock 124 bracket, with 500E 18mm bushing, on the 20mm bar, will be the absolute simplest & easiest solution.
A2023260226 is for most all other 202, 208, 210. This is stamped steel. I also have a pair of these somewhere... again, forgot photos. Still available new, but spendy at $20 MSRP each. Should be plenty in junkyards.
I need to dig up both pairs and document them on my website.
I still think using the stock 124 bracket, with 500E 18mm bushing, on the 20mm bar, will be the absolute simplest & easiest solution.
please post in here when you find the brackets i would like to take a closer look, aluminum brackets have much better tolerances and has a chance to work and if it does it wouldn’t be a bad idea to make a reproduction if them, you have a good point there in using the stock 18 mm bushing on the 20 mm bar but in my opinion it would not last long, the bushing is already small and thin, if you put the 20 mm bar you will squish all the rubber out and after some driving there is a chance that the bishing will just rip apart, i would rather make it proper and not worry about itEPC shows A2103260026 for the E55 bracket, unique to that chassis in USA. This bracket is an aluminum block, not stamped steel but of course it's NLA. I have a pair of them somewhere but somehow forgot to take photos for my website.
A2023260226 is for most all other 202, 208, 210. This is stamped steel. I also have a pair of these somewhere... again, forgot photos. Still available new, but spendy at $20 MSRP each. Should be plenty in junkyards.
I need to dig up both pairs and document them on my website.
I still think using the stock 124 bracket, with 500E 18mm bushing, on the 20mm bar, will be the absolute simplest & easiest solution.
Bad news. I snagged a bracket from a 97 E420. It won't work. The regular W210 must use a different rear sway bar body mount than the AMG W210s.
In this first picture you can see the W124 rear bushing, then the regular W210 bracket, followed by the W124 bracket, and finally an E55 (W210 AMG) bushing. The W124 bushing fits perfectly in either the W124 bracket or the W210 bracket. The W210 bracket just uses a narrower bolt spread than the W124.
In this second picture you can see the original rear bushing from my W124 400E, and next to it is the 2103260481 20mm bushing from my E55 bar. The 20mm bushing will require the AMG specific aluminum bearing cap. Those being NLA, I think we're firmly in the territory of custom brackets for this.
I may play around with making a die that could potentially bend the bracket needed for this. That's the hard part. Everything else can be easily mail ordered. No promises, but I MIGHT be able to do this.
I will add, however, that I agree with Dave that the stock W124 brackets with the 18mm bushings is probably the best solution.
In this first picture you can see the W124 rear bushing, then the regular W210 bracket, followed by the W124 bracket, and finally an E55 (W210 AMG) bushing. The W124 bushing fits perfectly in either the W124 bracket or the W210 bracket. The W210 bracket just uses a narrower bolt spread than the W124.
In this second picture you can see the original rear bushing from my W124 400E, and next to it is the 2103260481 20mm bushing from my E55 bar. The 20mm bushing will require the AMG specific aluminum bearing cap. Those being NLA, I think we're firmly in the territory of custom brackets for this.
I may play around with making a die that could potentially bend the bracket needed for this. That's the hard part. Everything else can be easily mail ordered. No promises, but I MIGHT be able to do this.
I will add, however, that I agree with Dave that the stock W124 brackets with the 18mm bushings is probably the best solution.
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so what i understand is that the aluminum bracket from the e55 should bolt in to the stock location on w124?
Right. There is no bolt in solution, aside from the 18mm W124 bushing.
I just noticed that in my previous post my second picture didn't actually load. If one of the mods wants to drop this picture in there, since it's been too long for me to edit it myself, that might help avoid confusion for anyone referencing this in the future. This should go right after the picture I posted of the two brackets and two bushings.
hi everyone, so i ordered a bracket from W210 part # A2023260226, this is a standard bracket for W210 it is not for a 20mm bushing, looks like the same size as stock W124 bracket, even though the part number suggests that it is for 20mm bushing i can confirm that is not, at this point i don’t know what is the part number for the correct metal bracket for the 20mm bushing, i was hoping to see what modifications i can make to make it fit but since its not the right bracket next step is to make a custom bracket. I dont know what would be the cost for a custom bracket i will post an update later when ill have it made, its very unfortunate that this specific bracket is so difficult, for people who’ve would like custom bracket i will post what would be the price, but if you are comfortable using the stock bracket and bushing on a 20mm bar its up to your personal choice
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more details, so i took some measurements of the stock bracket from 500E and i am very confident that is possible to make a stamped bracket for the 20mm bushing no problem, the only difference it will be that you will have to use bolts with a socket head for better clearance, here is my measurements, my mext step will be to make a custom set of brackets so i can mount the sway bar to confirm the proper fitment so i can tell the manufacturer to start making the bars, and after that will look into some options of making brackets
the shiny new bracket is from W210 the dirty one is W124
the shiny new bracket is from W210 the dirty one is W124
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hi everyone, so here is an update
i found the best possible solution for the rear 20mm seay bar bushing and bracket
i installed the custom 20mm rear sway bar on my 500E and it wasn’t a walk in the park, i never done it before so it took me sime time.
there is some small modifications to be made in order to fit the 20mm bar
you will need a new U-bolt for the SLS system to be able to mount it to the sway bar, the stok U-bolt is to small, then you need to enlarge the holes on the SLS bracket to be able to fit the bigger U-bolt
the brackets for the bar will need a small modification to the bolt holes, a very very minor grinding, the new bracket holes are just a smidge wider than the stock bracket holes
i found the best possible solution for the rear 20mm seay bar bushing and bracket
i installed the custom 20mm rear sway bar on my 500E and it wasn’t a walk in the park, i never done it before so it took me sime time.
there is some small modifications to be made in order to fit the 20mm bar
you will need a new U-bolt for the SLS system to be able to mount it to the sway bar, the stok U-bolt is to small, then you need to enlarge the holes on the SLS bracket to be able to fit the bigger U-bolt
the brackets for the bar will need a small modification to the bolt holes, a very very minor grinding, the new bracket holes are just a smidge wider than the stock bracket holes
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here is the part numbers for the bushings and the brackets
i hope you all are okey using honda parts on a mercedes, these in my opinion are the cheapest alternative compared to a custom bracket, available at any honda/acura dealer
anytime, and the part is pretty solid and sturdy very thick bracket material
i hope you all are okey using honda parts on a mercedes, these in my opinion are the cheapest alternative compared to a custom bracket, available at any honda/acura dealer
anytime, and the part is pretty solid and sturdy very thick bracket material
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Only concern with the Honda bushing is potential noise over time. The Mercedes bushings have a Teflon-impregnated cloth lining which keeps them silent. Hopefully the bare-rubber bushing remains quiet.
Also, one huge deal that needs careful inspection: Make sure the new, longer U-bolt does not come anywhere near the SLS pipes! See photo below. Disconnect the sway bar ends and rotate the bar up/down, verify there is plenty of clearance. If the bolt touches the pipe, it WILL eventually cut a hole in the pipe, and this is a nightmare to fix (don't ask how I know). Cut the excess threads off the U-bolt as needed.
Also, one huge deal that needs careful inspection: Make sure the new, longer U-bolt does not come anywhere near the SLS pipes! See photo below. Disconnect the sway bar ends and rotate the bar up/down, verify there is plenty of clearance. If the bolt touches the pipe, it WILL eventually cut a hole in the pipe, and this is a nightmare to fix (don't ask how I know). Cut the excess threads off the U-bolt as needed.
I did stumble across another interesting tidbit. The AMG E50/E60, based on the 210.072 chassis which was only produced in 1996-97, uses a special HWA- bushing with the standard steel bracket! I have a feeling this bushing allows a 20mm bar to fit the standard W210 (and probably W124) steel bracket.
This unique, 1-chassis-only bushing HWA-210-326-01-81 is available, but very expensive, ~$50 each from discount dealers. IF this is correct (won't know for sure until someone can confirm), it would be the "proper" way to fit a 20mm bar onto a 124 with standard brackets. @WDB748372 is investigating this option in case anyone would prefer to use factory bushings with the Teflon liner.
https://parts.mbofcovington.com/oem-parts/mercedes-benz-rubber-mount-wa2103260181
This unique, 1-chassis-only bushing HWA-210-326-01-81 is available, but very expensive, ~$50 each from discount dealers. IF this is correct (won't know for sure until someone can confirm), it would be the "proper" way to fit a 20mm bar onto a 124 with standard brackets. @WDB748372 is investigating this option in case anyone would prefer to use factory bushings with the Teflon liner.
https://parts.mbofcovington.com/oem-parts/mercedes-benz-rubber-mount-wa2103260181
For the U-bolt, the E55 AMG part may work, p/n 129-328-02-26. This shows as Backordered / Currently Unavailable at most online dealers, but that just means it's special order from Germany. MB Classic says it's still available. MSRP $4.90, discount $3.75 or so.
For reference, the E55 bracket for 20mm bar is p/n 210-328-02-27, MSRP $4 / discount $3. I do not know if this will work on the 124 chassis though, it may be a different shape / different design. I bought one 10+ years ago, I need to try and find it and take photos.
For reference, the E55 bracket for 20mm bar is p/n 210-328-02-27, MSRP $4 / discount $3. I do not know if this will work on the 124 chassis though, it may be a different shape / different design. I bought one 10+ years ago, I need to try and find it and take photos.
will do that, thank you
on the bushings side of things, i just tried to find a cheaper alternative, if anyone is not satisfied there is always the custom bracket rout wich is probably a few hundred bucks, in my opinion the honda parts a great value for the price
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Yeah, it's not a bad option. Nice to know.
if you zoom in you can see the scratch marks on the black bracket that shows how much it needs to be grinded
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I have bought from Betts spring manufacturing over the years. Old company, nice people to deal with. Their truck spring I have not had a problem with!
I would be interested in a set of the swaybars! Count me in.
ill keep you in mind, once the bars are made ill let everyone know
First of all; Very cool project!
However; When I sent the link to some more performance-oriented MB-friends one of them mentioned that he recently bought a new front swaybar from Eibach with the same dimensions. They do not offer an upgraded rear swaybar though, which to my knowledge is the most important piece of kit to make the car more oversteery
However; When I sent the link to some more performance-oriented MB-friends one of them mentioned that he recently bought a new front swaybar from Eibach with the same dimensions. They do not offer an upgraded rear swaybar though, which to my knowledge is the most important piece of kit to make the car more oversteery
Any details on the Eibach front sway bar? Was this for V8 cars, or 4/5/6-cyl chassis?However; When I sent the link to some more performance-oriented MB-friends one of them mentioned that he recently bought a new front swaybar from Eibach with the same dimensions. They do not offer an upgraded rear swaybar though, which to my knowledge is the most important piece of kit to make the car more oversteery
And yes, I've not seen any rear bars of 18-20mm diameter specifically for 124 chassis. The 210 rear bar requires modifications to fit and is overall not an ideal item for any 124 chassis.
do uou mind sharing the linck from where they bought the front sway bar? because to my knowledge they discontinued the bars for W124 and second the ones they use to sell were only for inline 6 enginesFirst of all; Very cool project!
However; When I sent the link to some more performance-oriented MB-friends one of them mentioned that he recently bought a new front swaybar from Eibach with the same dimensions. They do not offer an upgraded rear swaybar though, which to my knowledge is the most important piece of kit to make the car more oversteery
also if i remember correctly the eibach bars were 28 mm not 30mmFirst of all; Very cool project!
However; When I sent the link to some more performance-oriented MB-friends one of them mentioned that he recently bought a new front swaybar from Eibach with the same dimensions. They do not offer an upgraded rear swaybar though, which to my knowledge is the most important piece of kit to make the car more oversteery
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