There are several major differences between the 3-Piece BajaRon Sway Bar Kit for the Ryker. And the BRP 1-Piece upgrade bar kit. They have been well outlined in the posts above. But let me try to consolidate all the information in 1 place. Not to bore you. But a little background as to how we arrived at our present configuration.
In developing a sway bar for the Ryker. The 1st thing we did was to purchase a factory BRP upgrade bar kit and install it. As is the case with all of our products. If we can't improve on what is already available, we don't make it.
We found the install of the OEM bar to be quite difficult. This did not bode well for a future BajaRon Bar Kit. Some fairly major components have to be disassembled to get this job done. Most notably, the lower A-Arm. Then we found it extremely difficult to install the new BRP bar without scratching it up badly. The BRP bar does improve handling a good amount. But we found that adding additional strength in the bar assembly increased handling and stability even more.
A number of my vendors also do sway bar installs. Several of us were networking on this initial BRP bar install hoping to find a better, easier way to get it done. Not only for ourselves, but also knowing that DYI customers were not going to be happy with the factory method. After a few days of back and forth. Each one of these vendors told me they were not interested in doing any sway bar installs of the BRP or similar sway bar. It just wasn't worth the aggravation to them. This is when I knew I'd have to hit the drawing board, or abandon the project altogether.
I was already familiar with 3-piece sway bars. These are usually reserved for racing or high end applications, as it is a more expensive production process. But we found that by making the torsion portion of the bar just 1 straight piece, we avoided all of the serious component removal issues. And, if care is taken, the scratching of the bar can also be avoided. You don't even have to remove a wheel with this approach. But none of this did us any good if we had to remove the old bar as is. All the same components would have to be removed to do this. Erasing all the advantages of the 3 piece bar install process. So, we decided to cut the OEM bar which made removal very easy. It comes right out. But would customers be willing to cut the old bar? The old bar has no value, so that was not an issue. But even I was a bit nervous about the prospect. Fortunately, we found it to be much simpler, safer and easier than we'd expected.
The key here is, if you use an angle grinder, (the quickest, easiest method). It is imperative that you use a Cut-Off disk or blade, NOT the grinding wheel that came with your grinder. Some customers (and at least 1 video I've watched) struggle with this 'Cut the Bar' step because they use a grinding wheel instead of the recommended cut-off wheel.
The best way to go is a metal, diamond cut-off disk. These are very thin. Usually about 1/16". These go through the stock bar like a hot knife through butter. And the grinder is easily controlled. Here is an example. You can get these for under $15.00
The next best thing is an abrasive cut-off disk like this. Not quite as nice as the diamond wheel above. But do-able. These are typically 1/8" wide and can be had for around $5.00.
What you don't want is a grinding wheel. Typically these are at least 1/4" wide. It's just too much surface area making it difficult to control the grinder. This is what causes people difficulty. These wheels are designed to grind with the face of the wheel. Not cut with the edge.
Abrasive Cut-Off disk on the Left. Grinding Wheel on the right. The Metal/Diamond blade is about 1/2 the width of the abrasive cut-off disk pictured here.
But for those squeamish about Plan A, there are several alternatives, depending on what you have for tools. A cheap and easy alternative is a tight space hacksaw. These come in many configurations. This will take a bit longer. But even this manual approach doesn't take all that long. There is an example pictured in the post above. Again, there is a video out there showing the poor guy taking forever with a hack saw. First, he uses a full size hacksaw handle, which is really too big for the space available. And I'm not sure what he was using for blades. But a good blade designed for metal, installed the right direction (hacksaw blades are directional) makes the job quite reasonable.
Other than ease of installation, there are other functional differences between the 1-Piece BRP upgrade bar and the 3-Piece BajaRon bar. These include Billet Aluminum Arms. Of course they look great being anodized and etched to match the end links. But beyond the bling, they are quite functional. Because a 1-piece sway bar, being all spring steel, the bends (or arm portion) also flexes. You really don't want the arms to flex as it diminishes the function of the sway bar by absorbing energy that the bar is attempting to transfer to the other side. This unwanted flex is compensated for by increasing the strength of the bar steel on a 1-piece bar.
With a 3-piece bar. A relatively smaller diameter bar will work like a larger diameter bar because the arm flex has been reduced to zero with the billet arms. This also applies in a similar way to the end links. The BajaRon Billet Aluminum and Chromoly Steel End Links eliminate the stretch and compression which occurs in the factory plastic end links, increasing response and efficiency of the sway bar system. Not to mention that they look pretty good and you also eliminate the possibility of breakage.
Here is a picture of one of our prototype Ryker Sway Bar setups. Here you can clearly see that the billet arms mount to the straight sway bar. And the Billet End Links attach the arms to the Ryker's suspension.
Here is a question that I get all the time.
'Will the BajaRon End Links work with the stock sway bar or the BRP upgrade sway bar?' The answer is yes, they will work great with the BRP bars. Though I have to say that many come back, after a time, for the rest of the bar kit because they find that they want all the improvement they can get from the system.