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Suspension refresh

CBschnell

PCGB Member
Member
So I have started a refresh of the suspension on my 89 turbo. I have the M030 option so I bought replacement rear adjustable Konis, and I have removed the fronts and delivered to IG Racing (Ian Gardner) for a rebuild. There is approximately 5 weeks for the rebuild as Ian is very busy, which is giving me time to go through the suspension and replace/upgrade 33 year old parts. I have a deadline as I'm booked into Center Gravity at the end of November!
With the front shocks off, I am now going to clean up some components and paint them - springs and top/bottom washers. The rubber stops were totally perished but the top strut mounts look good.
[attachment=IMG_5643.JPG] [attachment=IMG_5646.JPG]
Today I removed the rear anti-roll bar and loosened all the bolts for the front anti-roll bar. I'm going to get both blasted and I will paint them. I will replace the bushes and use new bolts. The front wishbone bushes need replacing so that will be done.
Off to a good start, let's hope it continues...
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Hey Funnily enough.....

I've just started the same job at the front end of my '88 Silver rose (but not...) - I bought 2 x rear shocks from Ian last year - annoying clunk in the front right so started pulling it all apart. Ball joint is loose but not too bad - seems to be the main 'hinge' with rubber/ steel inserts that sits in the cross member. Anyhow all apart and as per yourself front shocks will be going off to IG for refresh & refurb - this is now the 2nd time I've done this job in my ownership of the car :)

 
If it's the second time, you have at least "enjoyed" the car a lot. As you have already done it once, I know who to contact! What did you do with your springs - clean and paint, or replace?

Look forward to reading about your progress.

 
Hi - reference the springs - I had a custom pair made to my spec by PI coils springs in Sheffield - I sent them one of the original ones then they made slightly shorter, dual rate & uprated springs for me - was a while ago but only cost ~ Ā£250.

Springs do snap ( especially BMW pigs tail bit) but they normally hold their form even when slightly rusty

 
I'm currently in a waiting stage. Ian is on schedule with the front shock rebuild. I took my ARBs and brackets to CFS near Northampton, and they will be blasting and powdercoating them. I have finally ordered all the new bushes - that took a while to determine best prices - only got 10% off and it was a chunk of money. I have gone with Powerflex for most of them. I have also purchased the Elephant rear wishbone castor bush, and I have gone with the adjustable droplinks for the rear ARB.

I need to replace one ball joint, so have ordered the ball joint repair kit. I will get the wishbones cleaned up as well before re-assembly. Without going into too much detail I have 3 front wishbones (no they were not all on the car at the same time!) and each ball joint looks to be different when looking from the bottom. One has a very clean almost rubberised base with a central grease nipple, another just shows the centre piece of the metal disk surrounded by flakey epoxy. And the other one had epoxy across the bottom, which I removed and then removed retaining circlip and metal disk, only to find a plastic moulded disk on top of another metal disk!! I have watched a bunch of Youtube videos and I have seen nothing like this one!

On another note I have been amazed at how the bolts have come off, with only one breaking (and that was probably my fault). I love PB Blaster and it's now my go-to release/penetrating spray. Compared to my 97 Defender where at least 50% of bolts broke or had to be cut out, it has been a pleasure.

I have taken this time to clean up the engine and wheel arches. The driver's side had a lot of grease and stuff. I suspect the power steering pump may need new gaskets/washers but now it's cleaned up, I can better determine what is happening and where once I have taken it out again.

 
Not quite suspension but file under while you are there... Apart from the rusty sills (to be replaced in near future) the car is in great shape. The only truly crusty pieces are the transmission oil cooler bracket and the fuel tank strap and cover. Decided to remove those today and took to CFS for blasting and powder-coating.

 
Quick update - I received my springs, ARBs, transmission oil cooler bracket and sundry bits from CFS, they look great. Check out the difference with how they looked in the earlier posts. I have most of the bushes, so I can start to reassemble.

[attachment=IMG_5750.JPG]

 
A quick update. I haven't started to reassemble as I'm waiting on some parts from Design911 and I'm guessing the part from Elephant is coming from the US - although they didn't say it would take so long when I ordered it! My rebuilt front Konis should be ready this week. This wait has been dangerous because I have been staring at the torsion bar assembly and have now decided to remove that! As everything else is getting cleaned up with new bushes, why not? It will be like a new car under there. So rear exhaust section is off and I will be cleaning up the exhaust brackets and heat shield, and whatever else looks in need of some love.

Just received the petrol tank cover and strap back - nice work by CFS.

Before shots

[attachment=IMG_5717 2.JPG] [attachment=IMG_5718 2.JPG]

And after...

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Looks good! I really need to start a rear end overhaul but it can wait. Last 3 years have seen gearbox, bodywork, engine, more bodywork! And lots more in all honesty. As my wife says, its like painting the Forth Road Bridge my car, never finished!

Stuart

 
Just picked up my rebuilt front Konis from Ian at IG Racing, and my parts finally arrived from Design911 - ordered on 9th Nov! I considered buying directly from Elephant but wasn't sure what the duty would be - at least I would have had an ETA. Waiting on the new nuts and bolts from OPC, and I will be able to install the front suspension. The back will wait until I have finished the rear clean-up.

[attachment=IMG_5798.JPG]

If anyone is considering new shocks, be advised Koni is increasing their prices in January after 2 increases already this year. Other manufacturers will be doing similar.

 
As most of you, who have been through this, already know, stuff happens and it takes longer than expected. My welder started on the sill refurb/replacement in December and that plus work has slowed me somewhat. Cutting into the sills and seeing that work come together has been interesting (the previous bodge attempts!), but we are nearly there and I will cover that in a different thread.

Anyhow today I finally removed the torsion bar carrier after first removing the trailing arms. The rear suspension area is now a blank canvas! Once I have the wheel bearings off, I will be sending the trailing arms and front control arms for vapour blasting. Interestingly while removing the ball joints from the control arms, I came across 2 different types of ball joint. This now makes 3 when you count the first control arm I messed up when the ball joint seemed to be one that wasn't designed to be replaced!

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I'm cleaning up the whole area and addressing any small rust spots, although in truth it looks in fantastic condition, albeit dirty - a testament to Porsche. the last step will be to drop the transmission and remove the cross member - to blast and powdercoat plus fix the top bush, probably use the resin procedure to create a new one.

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I have a couple of bushes to buy for the torsion bar assembly and rear trailing arms, but that should be it... plus new nuts and bolts.

 
I finally got the wishbones and torsion bar bearing flanges off to Vapour Blasting Northants - the only thing holding back taking the trailing arms is I can't get the ABS sensors out - I have tried WD40, using a punch to try and turn the base of the sensor, etc. Any recommendations on removing them? Thanks

 
Quick turn-around on parts being cleaned - looking like new after 34 years...

[attachment=Blasted suspension.jpeg]

Before shot...

[attachment=pre blast suspension.jpeg]

 
I understand originality is important for some restorations. But seem to recall from years ago that refurbing MO30 Konis was a similar price to a new set of KW's. I paid around Ā£1100 for a new set of KW's, think they've gone up quite a lot since then though.

 
I'm taking a practical approach to my restoration - updating when it makes sense with no strict adherence to OEM. I went with the Konis without much thought, and they have cost about Ā£850 (new rears and rebuilt fronts). They have all gone up in price with several increases over the last 9 months so I imagine the KWs will be quite a bit more now. With the bushes I have gone mainly Powerflex, along with a drop link for the rear and the Elephant rear front wishbone bush. I have cleaned up the ARBs, the front wishbones are cleaned up and now I will install the Rennline ball joints. The torsion bar carrier was dropped off today for blasting and powdercoating and I will post an image when I get that back.

I'm dropping off the trailing arms tomorrow for vapour blasting. Those damn sensors were dogs to get out - I wish I had read the Rennlist article sooner - essentially just drill and hammer them out. I then had a similar issue with the metal sleeves for the rear bush of the trailing arm - man they didn't want to shift. Rennlist to the rescue again. https://rennlist.com/forums/924-931-944-951-968-forum/830146-can-t-remove-control-arm-bushing-liners.html

I used the hacksaw method with lots of WD40 and heat.

As you may have seen, this was a suspension refresh but whilst you are there... I have already posted about the rear fuel line, so I will be upgrading that whilst everything is off. The next thing is to drop the transmission slightly and take off the cross member to have that cleaned up, and then to probably use the poly method to make good the transmission mount.

I am keeping track of the costs, which I tend to look at after a few drinks!

 

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