9049 - Splined Collar - 1 1/8"-48 Spline, 1 5/8" OD X 1.25 LONG
SKU 9049
Category: High-Strength Splined Sway Bar & Torsion Bar Collars (Off-Road Fabrication Hardware)
Engineered for mid-sized off-road race vehicles, custom rock crawlers, long-travel pre-runners, and specialized desert racing buggies, this 1.625" outer diameter splined collar provides a rock-solid, zero-slop connection for custom anti-roll systems and bespoke torsion bar keys. Standard pinned, clamped, or keyed sway bar setups are highly prone to wallowing out, shearing, or introducing dangerous mechanical play when subjected to harsh, cyclic off-road articulation. This premium fabricator component solves that weakness via an internal, fine-tooth spline layout. It is explicitly engineered to distribute massive torsional twisting forces evenly across the contact area, ensuring your suspension tracking remains predictable, crisp, and completely rigid.
Performance & Fitment
Application: Ideal for custom chassis fabrication, intermediate off-road sway bar linkages, adjusters, and fabricating bespoke torsion bar keys.
Internal Spline Profile: 1 ⅛" – 48-Spline (Industry-standard intermediate racing spline specification chosen for its dense mechanical indexing and superior torque capacity).
Outer Diameter (OD): 1.625" (Engineered with a heavy-wall cross-section to handle intense twisting loads without flexing or splitting).
Overall Length: 1.25" (Compact profile designed to provide deep spline engagement while maintaining clearance for tight suspension packaging).
Alignment Profile: Features a precise 45° edge chamfer to ensure smooth, non-binding alignment and easy fitment onto matching splined shafts.
Premium Construction
Material: 10XX Series Structural Steel. Specifically selected for its excellent metallurgical balance, offering immense tensile yield strength paired with excellent weldability when joining the collar to chromoly or mild steel fabrication arms.
Manufacturing Process: Precision Machined & Broached. CNC-machined on all critical outer profiles and interior-broached to exact tolerances. This guarantees a flawless, smooth slip-fit onto matching 1 ⅛" 48-spline bars, eliminating microscopic play without binding.
Design Stability: Engineered to maintain absolute dimensional roundness and structural integrity throughout the welding process and under severe dynamic loading.
🛠️ Custom Off-Road Sway Bar Welding & Engineering Tech Notes
Integrating splined collars into a custom anti-roll bar system requires precise fabrication techniques to avoid altering the metallurgy or ruining the fitment:
🧼 Critical Pre-Weld Preparation: Before welding this 10XX series steel collar to your custom sway bar arms, all manufacturing oils, storage coatings, and surface scales must be completely removed. Thoroughly scrub the inner splines and outer weld bevels with clean brake cleaner and a wire brush. Any oil trapped in the splines or on the weld face will introduce porosity and hydrogen contamination into the weld puddle, severely weakening the joint and risking a catastrophic failure under suspension load.
🔥 Manage Heat Input & Prevent Spline Distortion: When TIG or MIG welding your sway bar arms to this collar, excessive heat can warp the round body, causing the internal splines to shrink or pull out of round. To minimize thermal distortion, clamp or slide the collar onto a scrap piece of 1 ⅛" 48-spline bar stock during the welding process to act as a heat sink and dimensional mandrel. Use a staggered welding pattern—alternating sides and allowing the component to cool slightly between passes—rather than laying down one continuous, high-heat bead.
❄️ Always Allow Slow, Natural Cooling: Never quench the collar in water or oil after welding to cool it down quickly. Rapid cooling of hot structural steel alters its crystalline molecular structure, making the metal incredibly brittle around the heat-affected zone (HAZ). This creates a high-stress fracture point right where the arm meets the collar. Allow the completed assembly to cool slowly and naturally in still air at room temperature.
📐 Aligning Timing and Indexing Marks: When fabricating a dual-arm sway bar assembly, the splined collars on both the left and right arms must be welded in exact geometric alignment (properly "timed" with each other). If the collars are welded out of alignment by even a single spline tooth relative to the arms, the sway bar will be pre-loaded when installed, causing the vehicle to sit crookedly and track poorly. Double-check your jigging and spline indexing before laying down your final weld tacks.
🛢️ Post-Fabrication Spline Lubrication: While the outer body will be painted or powder-coated after fabrication, the internal 1 ⅛" 48-spline teeth must remain bare metal to slip onto the sway bar. To prevent rust pitting and unwanted metal-on-metal galling caused by fine trail silt working its way into the assembly, apply a thin layer of high-pressure, water-resistant marine grease or anti-seize compound to the internal splines prior to final installation.
What’s Included
(1) 1 1/8″-48 Splined Collar
Stock Information
19 in stock (can be backordered)
Warranty
Backed by a 1-year warranty for peace of mind.