When I bought my S30 4 years ago I noticed the threaded end links that attached the swaybar ends to the lower control arms in the front needed some attention. The top end of the threaded end link had been rubbing the opening inside the sway bar end to a point where nearly half the material was gone from the end link. I replaced both sides and fitted new polyurethane bushings at the same time.

I happened to be looking under there last night and found that the same thing had again happened. Problem is that now the opening in the sway bar end is no longer circular... it's become potatoe shaped and I can only see this getting worse in the future. My front swaybar is a 1" diameter one. What should I do? Replace the swaybar with a new one because of this? sleeve the opening in the swaybar end so that it's a tighter fit with the threaded end?

Curious if any one else has seen this happen?

-e

If the swaybar itself is wearing thats unusual and indicates something wrong. Assuming that the link bushes are fitted correctly, I'd be looking at the alignment of the links in relation to the bar.

It also just possibly could have something to do with that large bar you are using, 1" = ~26mm, ~22mm would be better for a street car, increase the spring rates and get the best shocks you can afford if you want a better handling suspension