Working on an Electric Sway Bar Bypass

[Retired BLM Rig]

As some of you know, I've been working on a way to control the sway bar disconnect to liberate it from the nannies that constrain it and give the driver full control to make it work when they want, rather than when the truck allows. It's nice that Ram permits it to work in 4Hi and 4Lo, but what about those times when you're traveling down a nice dirt road and you don't need 4WD. My main complaint has been with the 18 MPH speed limit that causes it to reconnect. There have been lots of times that I could've enjoyed a softer ride at 25-30 MPH if it would stay disconnected.

I realize that there are already options out there for manual, air and cable controlled SmartBars, but at this point no one has come up with a simple electric system that can be controlled from the drivers seat. What if you don't want to plumb an OBA system into your truck or you don't want to have to crawl under your truck each time you need to disconnect/reconnect? Well, suffice it to say that those days are behind me now and I'm working on a plug and play solution that will make it available for you too.

The first prototype that I was working on is just a simple adapter plate that outlines the shape of the SmartBar module and holds the new electric actuator and is controlled by a rocker switch.

Prototype 1.0 adapter plate installed on sway bar

Elec. S.B.1.JPG (17.77 KiB) Viewed 10106 times

Prototype 1.0 adapter plate and actuator

Elec. S.B.2.JPG (15.51 KiB) Viewed 10106 times

The only problem is, you still need to have the SmartBar module plugged into the truck to maintain locker function, so it would need to be relocated out of the way (mounted to the frame, zip tied to the crossmember or tucked up out of the way in the engine bay). However, one of our members (Oilbrnr) suggested incorporating a mounting bracket into the adapter plate, which has resulted in prototype 2.0.

Prototype 2.0 adapter plate installed on sway bar

IMG_2370.JPG (20.22 KiB) Viewed 10106 times

New actuator installed

IMG_2373.JPG (19.6 KiB) Viewed 10106 times

SmartBar module mounted to bracket

IMG_2374.JPG (20.24 KiB) Viewed 10106 times

As I stated earlier, this would be a standalone, plug and play bypass that is not controlled by the factory switch but from a separate rocker switch. There are still some hurdles to overcome like...

• Keeping the exposed end of the factory SmartBar module protected from the elements

• Finding the right switch to use (most modern indicator light switches use an LED which is polarity sensitive, but this system is reverse polarity; ground trigger, positive indicator signal) I need a switch with an incandescent indicator bulb

• Being on a waiting list with the local machine shop to mass produce the adapter plate

• Testing the fit on a 4th gen to make sure everything has clearance

...To name a few, but the basic functionality has been figured out.

I'm sure the first question going through everyones mind is "How much?". I'm still waiting on a quote from the machine shop, but I'm hoping to keep it right around $249. Considering that the other options for remote control functionality are more expensive and require the purchase of an OBA system, or more labor intensive to install the cable controlled option, I'm hoping that others will see this as being a reasonable price point.

Anyhow, I just wanted to provide an update because it's been about six weeks since the last discussion on this topic. I've been driving with the prototype on my truck and I must say, intersection and driveway transitions are much nicer disconnected, not to mention the off road benefits. Please feel free to respond with positive and negative comments, questions, ideas and input on this subject.

Thanks for taking the time to read all this!

[Retired BLM Rig]

A couple of you have private messaged me to inform me that this thread is locked (possibly all my vendor threads).
I don't know what's going on with it, the settings all look fine on my end. I've contacted the administrator to ask for help.
Thank you for your patience!

[AceMan]

test tttt

[Bill2014]

Keep up the good work!

[Idaho RC]

Very interested and looking to be first in line for an order.

[Pasopwagon]

Can’t wait to see the finished product


2013 Power Wagon
San Luis Obispo County California
www.acroweld.com

[Oilbrnr]

Only took me 52 years to come up with a good idea!

It would make my first and last three miles of the trip in and out of my house on dirt, much softer.

[Retired BLM Rig]

I had the opportunity to look at a 2019 and test fit the prototype:

2019 Stock SmartBar module.

My main concern was if there would be clearance issues with the crossmember and fan shroud.

The adapter plate fits with room to spare.

Clears the crossmember.

Clears the fan shroud.

The only thing that's close is the plastic oil filter drain tray, but I don't think that will be a problem.

Fan shroud clearance with SmartBar module installed.

Crossmember clearance with SmartBar module installed.

Conclusion... Yes this will work on all generations of Power Wagon

[Retired BLM Rig]

A short update:

This is the switch I'm going to use, the indicator light is an incandescent bulb, so it works with the reverse polarity of the system (unlike an LED switch). The indicator light will only illuminate after the actuator has reached the end of it's stroke. It will come with an under-dash mounting bezel, for those of you that don't want to drill a 3/4" hole in your dashboard.

RoundRockerSw.jpg (52.73 KiB) Viewed 9854 times

The prototype adapter plate/bracket is at the waterjet shop and should be done by the end of the week. Here's a waterjet video for you to check out if you're unfamiliar with it.

phpBB [video]

Clickable link for Tapatalk

[Oilbrnr]

Got some pretty decent rains yesterday here in the Phoenix area, and the road to my house is in pretty bad shape until myself and others get out to drag it with our tractors. Made me think this morning how nice it be to keep that bar disconnected for the 3 mile trek, twice a day.

[OffroadTreks]

I'm sure the first question going through everyones mind is "How much?". I'm still waiting on a quote from the machine shop, but I'm hoping to keep it right around $249. Considering that the other options for remote control functionality are more expensive and require the purchase of an OBA system, or more labor intensive to install the cable controlled option, I'm hoping that others will see this as being a reasonable price point.

Anyhow, I just wanted to provide an update because it's been about six weeks since the last discussion on this topic. I've been driving with the prototype on my truck and I must say, intersection and driveway transitions are much nicer disconnected, not to mention the off road benefits. Please feel free to respond with positive and negative comments, questions, ideas and input on this subject.

Thanks for taking the time to read all this!

You're going to have a larger market than just PW guys. Start thinking about that seriously. Because the current manual and OBA verison are sold and marketed to Jeepers. But they work both ways. Mine works on my 2018 Jeep JL Wrangler Rubicon. Still using the same damn smart bar.

Might be time for you to setup a website dude.

[EasyDoesIt]

I'm sure the first question going through everyones mind is "How much?". I'm still waiting on a quote from the machine shop, but I'm hoping to keep it right around $249. Considering that the other options for remote control functionality are more expensive and require the purchase of an OBA system, or more labor intensive to install the cable controlled option, I'm hoping that others will see this as being a reasonable price point.

Anyhow, I just wanted to provide an update because it's been about six weeks since the last discussion on this topic. I've been driving with the prototype on my truck and I must say, intersection and driveway transitions are much nicer disconnected, not to mention the off road benefits. Please feel free to respond with positive and negative comments, questions, ideas and input on this subject.

Thanks for taking the time to read all this!

You're going to have a larger market than just PW guys. Start thinking about that seriously. Because the current manual and OBA verison are sold and marketed to Jeepers. But they work both ways. Mine works on my 2018 Jeep JL Wrangler Rubicon. Still using the same damn smart bar.

Might be time for you to setup a website dude.

What he said.

I like Shopify and Google Domains.

[PWJouster]

haha i said this same thing to him...Can not ignore the true market potential of this product.

copied from a private message to BLM-

WHATEVER YOU DO, ADDRESS THE JEEPS- HUGE RUBICON MARKET.

lol

[PWJouster]

considering im looking at a used rubicon for a second vehicle.

[Retired BLM Rig]

You're going to have a larger market than just PW guys. Start thinking about that seriously. Because the current manual and OBA verison are sold and marketed to Jeepers. But they work both ways. Mine works on my 2018 Jeep JL Wrangler Rubicon. Still using the same damn smart bar.

Might be time for you to setup a website dude.

The interesting thing about the Rubicon SmartBar is that it's just a sway bar motor, no locker guts inside. On the JK the lockers are controlled with dedicated relays, so you can remove the SmartBar without effecting the lockers. The only down side is the sway bar light will flash on the dashboard, so you have to use a ProCal or similar device to deactivate the light. I already have the wiring harness figured out for the JK and it would use my first prototype adapter plate for mounting the new actuator. It's the same on the JL but I'm still working on the harness layout. It shouldn't be an issue just a matter of time.

Does anybody know where I can find a good front end developer?

[Retired BLM Rig]

For those of you wondering about the actuator I'm using... it comes to me in this box.

[olyelr]

Keep up the good work!

[Retired BLM Rig]

A short update on this project: I thought I was going to be able to control the new Sway Bar Bypass with the factory switches, however, beta testing has revealed an issue with the 2013-18 trucks. The CAN-BUS circuitry was changed in 2013 and inhibits me from using the OEM dash buttons. Fortunately though, a dedicated rocker switch will still do the job. Instead of integrating this into the Locker Bypass, like I was hoping, it will just be a standalone unit for controlling the sway bar. A new test unit has been sent out, just waiting for confirmation that everything works as it should.

[BULLITT1204]

So with it being stand alone im guessing the truck switches wont show if the disconnected or connected then correct. And pretty kuch u gotta just feel when its disco vs connected???

[Retired BLM Rig]

So with it being stand alone im guessing the truck switches wont show if the disconnected or connected then correct. And pretty kuch u gotta just feel when its disco vs connected???

The factory switches will always indicate that it’s connected and won’t have any flashing lights, but the new rocker switch that I provide with the system has its own indicator light to show when it’s connected or disconnected.

[SimonandSimonBeast]

A short update on this project: I thought I was going to be able to control the new Sway Bar Bypass with the factory switches, however, beta testing has revealed an issue with the 2013-18 trucks. The CAN-BUS circuitry was changed in 2013 and inhibits me from using the OEM dash buttons. Fortunately though, a dedicated rocker switch will still do the job. Instead of integrating this into the Locker Bypass, like I was hoping, it will just be a standalone unit for controlling the sway bar. A new test unit has been sent out, just waiting for confirmation that everything works as it should.

I know you say this issue with the swaybar control affects 2013-2018. Just for clarity, is that 2013.5 - 2018? In other words, does it affect the 2013 with 4 link / rear leaf truck?

Sent from my Moto Z (2) using Tapatalk

[Retired BLM Rig]

A short update on this project: I thought I was going to be able to control the new Sway Bar Bypass with the factory switches, however, beta testing has revealed an issue with the 2013-18 trucks. The CAN-BUS circuitry was changed in 2013 and inhibits me from using the OEM dash buttons. Fortunately though, a dedicated rocker switch will still do the job. Instead of integrating this into the Locker Bypass, like I was hoping, it will just be a standalone unit for controlling the sway bar. A new test unit has been sent out, just waiting for confirmation that everything works as it should.

I know you say this issue with the swaybar control affects 2013-2018. Just for clarity, is that 2013.5 - 2018? In other words, does it affect the 2013 with 4 link / rear leaf truck?

Sent from my Moto Z (2) using Tapatalk

Locate this 10 pin connector on the passenger side vertical radiator core support frame.
Count the number of wires in the connector:

• 9 Wires = It might work

• 10 Wires = It won't work

[SimonandSimonBeast]

10 wires.

Sent from my Moto Z (2) using Tapatalk

[SimonandSimonBeast]

A short update on this project: I thought I was going to be able to control the new Sway Bar Bypass with the factory switches, however, beta testing has revealed an issue with the 2013-18 trucks. The CAN-BUS circuitry was changed in 2013 and inhibits me from using the OEM dash buttons. Fortunately though, a dedicated rocker switch will still do the job. Instead of integrating this into the Locker Bypass, like I was hoping, it will just be a standalone unit for controlling the sway bar. A new test unit has been sent out, just waiting for confirmation that everything works as it should.

I know you say this issue with the swaybar control affects 2013-2018. Just for clarity, is that 2013.5 - 2018? In other words, does it affect the 2013 with 4 link / rear leaf truck?

Sent from my Moto Z (2) using Tapatalk

Locate this 10 pin connector on the passenger side vertical radiator core support frame.
Count the number of wires in the connector:

• 9 Wires = It might work

• 10 Wires = It won't work

10 Pin Connector.jpeg

There are 10 wires going in and out of that connector on my truck. What does that mean regarding the bypass possibilities?

Sent from my Moto Z (2) using Tapatalk

[OffroadTreks]

I have a manual bypass. But to be honest, it's kind of annoying to crawl under the truck. I should get myself one of these.