If the exact size bushing isn't available, is it better to use one a tiny bit oversized or undersized?
The bar in question measures 1.136" (28.854mm) on my calipers. Energy Suspension lists a 1.125" (28.575mm) and a 29mm (1.142") bushing. So my options are a bushing that's .011" too small, or .006" too big.
Thoughts?
Too small would be good for the ID. Too big would be good for the OD. You can always squeeze it which would firm it up a tad, but loose is bad. Both because it allows more movement and degrades the effectiveness, and because movement speeds wear on the bushing.
Actually, I guess it doesn't matter--just noticed both bushings have the same part number. Energy Suspension is just being a little imprecise with their standard/metric conversion.
Sounds like you determined they're the same ID regardless so it's moot but I'd chose the slightly undersize ID. you could use sandpaper to slightly open the bushing ID up if you felt binding upon installation where as you couldn't take slop out of a too large bushing as easily.
Use the smaller bushing that's too tight on the sway bar. It'll probably install fine, if it doesn't, mill/sand out the ID a bit.
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