DIY Large Chassis Coilovers

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Re: DIY Large Chassis Coilovers

Postby jcarrick » Sun Dec 04, 2016 9:02 pm

I posted this in my build thread, but I figured I post it here as well.

I started doing the DIY Coilovers on my new urS6 Avant, and after getting the struts out, I realized that the rear Koni struts have a welded on spring perch. I re-read the different T44/urS DIY Coilover threads and could not find any info on how guys have dealt with this. I found one guy on Audizine who used, what looks like, some sort of snap ring, above the weld, for the sleeve to sit on, but personally it looked like it would eventually expand and slide over the weld. Does anyone have any experience with this? Would it be ok to just let the sleeve sit on the weld? I considered make a ring for it, like the front struts need, and just tacking it to the weld, but I figured I'd see if others have dealt with this first.

Image
-Jon

1995.5 urS6 Avant
2003 A4 Avant 1.8t
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Re: DIY Large Chassis Coilovers

Postby loxxrider » Sun Dec 04, 2016 9:09 pm

I guess this hasn't been dealt with because almost everyone has used Bilstein struts. If it were me, I'd make a ring of something to sit over the weld. You are right that the sleeve could eventually split. I'm sure you could do it for a while with no problems until you have time to come up with another solution though.

Also, the QA1 solution Nick came up with for the rears is really nice if you want to go that route instead.
-Chris

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Re: DIY Large Chassis Coilovers

Postby pilihp2 » Mon Dec 05, 2016 4:02 pm

Ringbearer had his sent out to Koni and they cut off the stock perch and welded on a ring for coilovers.
I plan on doing the same, some day....
In the meantime, I got a coil sleeve that was as tight as possible and just slipped it on and let it sit on the weld.
It's starting to crack, but it's been about 2 years now.
My next attempt while I procrastinate on sending them out to koni, is getting a ring that can sit ontop of the weld.

I need to re-valve mine soon though, so I might be sending mine out sooner rather than later.
-Phil
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Re: DIY Large Chassis Coilovers

Postby loxxrider » Mon Dec 05, 2016 7:52 pm

Well there you go. First hand experience!
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
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Re: DIY Large Chassis Coilovers

Postby jcarrick » Mon Dec 05, 2016 10:53 pm

I actually came up with a solution today.

Last night I was really not looking forward to cutting the rings out with the drill press/hole saw and was also trying to figure out what to do for the rear struts. I called the local steel shop, that I normally source my steel through, and asked if they had any 2.75" x .25" wall DOM and 2.5" x .25" wall DOM tube. I was in luck! I went down and picked up a foot of each. Then I used my horizontal band saw and cut .25" rings out of the two pieces of tubing.

Image

Since the Koni's were just a hair over 2" in diameter, I used a sandpaper flap wheel on a drill to open them up to where they would slide down the shock. They fit nice and tight and will just sit on top of the weld, like Chris suggested.

Image

Then I cut my OE spring perches off and lowered my steering arms. I turned my steering arms in just a hair, incase I want to run wider wheels/tires some day.

Image

I found that both of my front wheel bearings were loose, so I am having new ones pressed in tomorrow. Hopefully they will be done in the AM and I can get the car back on the road early in the day!

I have plenty of material left, if anyone needs some rings for their own DIY Coilovers. Just pay for the material cost and shipping!
-Jon

1995.5 urS6 Avant
2003 A4 Avant 1.8t
1997 F350 Fummins
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Re: DIY Large Chassis Coilovers

Postby pilihp2 » Mon Dec 05, 2016 11:13 pm

Dude,

I'm about to swap out strut housings, could totally use a set of front and rear rings for my koni's....

That's perfect.


PM me a price n stuff
-Phil
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Re: DIY Large Chassis Coilovers

Postby ringbearer » Mon Dec 05, 2016 11:17 pm

Looking good Jon!

My rear konis were stoopid expensive, get the qa1 rears going down the road and do a write up so others can enjoy the more affordable route.

I love my horizontal bandsaw too :)
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Re: DIY Large Chassis Coilovers

Postby jcarrick » Tue Dec 06, 2016 2:21 pm

ringbearer wrote:Looking good Jon!

My rear konis were stoopid expensive, get the qa1 rears going down the road and do a write up so others can enjoy the more affordable route.

I love my horizontal bandsaw too :)


QA1 rears will happen once the Koni's are worn out. I will definitely do a write up on installing them and maybe Chris can add it to the first post of this page for everyone.
-Jon

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2003 A4 Avant 1.8t
1997 F350 Fummins
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Re: DIY Large Chassis Coilovers

Postby PRY4SNO » Tue Dec 06, 2016 11:10 pm

loxxrider wrote:When you are all happy with your calculations and have made your cuts, get to welding!

Image

One thing to note about the welding process... You really want to get the two tube sections as close to concentric as possible. The easiest way to do this is to put a strut in the housing while you are welding. The problem with this technique is that the struts are filled with 1000s of pounds per square inch of pressure, and overheating one could cause it to fail and explode, potentially maiming or killing you and anyone around you. As a result, you must only weld small sections at a time and allow the strut to cool off after a few small passes. That's why the welds look so inconsistent in the pictures.


One thing we do for welding small bore piping is to get a pair of chain Vise Grips and a 1-foot chunk of angle iron sized to act as a saddle for the weld joint. Set the pipe ends centered on the angle, softly clamp down with the chain grips on each pipe/tube. Set your gap and clamp tight. Tack in three places, basically 12 and 6, then 3 or 9 o'clock. Tacking at 3 or 9 makes no difference, only need three total tacks with small bore. Then you're free to move the joint somewhere comfortable like a vise, and weld all the way around with out any interference.

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Re: DIY Large Chassis Coilovers

Postby loxxrider » Tue Dec 06, 2016 11:25 pm

Great progress and info for the thread. Thanks!
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
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Re: DIY Large Chassis Coilovers

Postby 90quattrocoupe » Fri Dec 09, 2016 8:29 pm

Or you could get an old shock out of the junk yard, drill it, drain it and keep it around for the next time you do welding on struts.

Or maybe something like these:

Image
Image

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Re: DIY Large Chassis Coilovers

Postby loxxrider » Fri Dec 09, 2016 8:47 pm

These days, I'd just machine something to fit. Busy gotta be careful not to weld it as well.
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
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Re: DIY Large Chassis Coilovers

Postby scubagli » Sat Dec 10, 2016 12:30 pm

Use copper.

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