Noisy sway bar Options

[blitZ]

I upgraded to a 22mm Weltmeister sway bar a few years ago. During some routine maintenance, I noticed it was hard to move. So, I removed it, cleaned and lubed the bushings and now moves freely. Ever since, I get a clunking sound when I hit a bump or hole in the road. I think it is adjusted correctly, there seems to be no load on it sitting flat.

There was a little side to side play and I limited it by adding some washers and felt material to snug up each side. Any ideas as to what is the cause?

[brant]

Probably you did this...
but when ever installing a bar its nearly impossible to get each side lined up perfectly... (plus these cars have a bit of variation even if you measure)

its critical to tweek things to get each side as much inline with the other during install as possible. Plus I ABSOLUTELY install zerks into bar bushings. I did so on my welts and also on my smart racing bars.

Once on the old race car (15 years back?) I ripped out a 6inch are of the inner fender where the sway bar bushing was. Thats when I learned that these bushings are a maintanence item and require frequent lube.
Once they bind, they tear

I'd remove it again... clean.. lube... and install zerks into the bushings.