Hey everyone, there has recently been some discussion about the strength of the stock control arm, specifically where the sway bar mounts. We've seen damage ranging from cracking to full on failures from users and shops alike. Since we have access to OEM Cad files and Finite Element Analysis software, we decided to look into the situation this afternoon.
Finite Element Analysis is the process in which computer models of specific parts are mathematically scrutinized for potential points of failure, the analysis takes into account geometrical design, material thickness and strength. In the graphical representation of this data below, blue indicates areas of relatively low stress, yellow areas of medium stress, and red of potential failure points.
This is the OEM Sway bar attachment point for the 2010 Camaro 5. This piece is welded onto the OEM control arm and the hole is where your sway bar endlink stud is pushed through. As you can see, there are localized areas of high stress directly above the hole... this backs up the physical evidence we've seen lately of endlinks pulling through that mount and rendering that control arm useless.
As per our analysis, we've come to the conclusion that the amount of torque that is placed on the endlink stud will have a negligible effect on the structural integrity of the thin metal that the bracket was designed from. What extra torque will do is possibly keep the nut from backing off of the stud, but will not prevent the failure of the bracket it's self. The real issue is the material used in the OEM bracket, and the thickness of the steel in question.
Here is a prototype design of a reinforcement bracket that we will be testing shortly. The design is incredibly simple and will take about 5 minutes to install. We're considering manufacturing this piece if there is enough interest in the forum. This plate will solve the fundamental issue of the material being too thin, without the need to replace your endlinks because the stud is too short.
If anyone has questions or concerns please let us know. We strongly feel this solution is elegant, simple and will resolve issues surrounding the stock bracket.