At least a couple problems with this approach, I think 1. effective length of torsion bar remaining available would be lessened, higher rotational deformation would be required of the remaining material that could twist, higher stresses result, different spring constant,... 2. local stresses in the region of the splice would probably be the killer These torsion bars are pretty high tech, and very much specifically engineered to the application. To do anything other than just replace the torsion bar with another intact bar would be dangerous. I certainly would not want that door falling on me if the bar failed. I think the stored energy that would be released when the bar failed (ie weight of the door up that high) would not be adequately absorbed by the strut absorber. If it fell on someone other than the owner, the door to a lawsuit would be wide open,... -----Original Message----- From: dmcnews@xxxxxxxxxxxxxxx [mailto:dmcnews@xxxxxxxxxxxxxxx] On Behalf Of Bob Brandys Sent: Tuesday, June 26, 2007 10:03 AM To: dmcnews@xxxxxxxxxxxxxxx Subject: Re: [DML] Torsion bars repair? I wonder if a machine shop could spline the two broken ends and then a coupling fabricated to keep them together? Moser who makes custom axles for cars might be able to do this. Bob To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnews Yahoo! Groups Links To address comments privately to the moderating team, please address: moderators@xxxxxxxxxxx For more info on the list, tech articles, cars for sale see www.dmcnews.com To search the archives or view files, log in at http://groups.yahoo.com/group/dmcnews Yahoo! Groups Links <*> To visit your group on the web, go to: http://groups.yahoo.com/group/dmcnews/ <*> Your email settings: Individual Email | Traditional <*> To change settings online go to: http://groups.yahoo.com/group/dmcnews/join (Yahoo! ID required) <*> To change settings via email: mailto:dmcnews-digest@xxxxxxxxxxxxxxx mailto:dmcnews-fullfeatured@xxxxxxxxxxxxxxx <*> To unsubscribe from this group, send an email to: dmcnews-unsubscribe@xxxxxxxxxxxxxxx <*> Your use of Yahoo! Groups is subject to: http://docs.yahoo.com/info/terms/