Suspension Refresh

Topics relating to the series 1 Exige
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dris
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Suspension Refresh

Post by dris » Fri Jan 16, 2015 7:08 pm

With winter upon us now is a good time as ever to do a suspension refresh.

Hopefully you can give me some advice as I go along.
Please forgive if im posting in the wrong area and mods move it appropriately.

I want to keep the car drivable on the road but also competent on track.
After talking with Nitron my plan is to replace the shocks and springs with Nitron 46 race pro shocks (1 way adjustable) and 450lb front 525lb rear springs with helpers all round.

Also I will replace all the original wishbone bushes with bearings and replace the ball joints, drop links, anti roll bar bushes, suspension bolts, uprated toe link kit, new discs and pads.
I am going to refurbish the wishbones by having them sandblasted , zinc passivated then coat with clear por-15.

Apart from the sandblasting of the wishbones I plan to do everything myself, I'm no trained mechanic but I believe there's more satisfaction to doing it yourself.

I'll be taking my time (as only a few hours per evening...2-3 times a week) but my aim is to finish beginning of March ready for Angelsey :-)

Edit: Part way through Day 4 I found an excellent guide http://www.tadts.com/instructions/suspe ... 00018.html

Day 1

Removed all the non-essential items from the sides of the garage.

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Loosened off the wheel nuts, jacking up at point A to put the car on ramps on one side.

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Removed the 2 rear under-trays and jacked up the car on the other side at Jack point A. This then allowed me to position axle stands at points B and D.

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After removing the wheels and placing them underneath the car this is the rear nearside.

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......and the front nearside (quite rusty…although the camera flash highlights more than the rear)

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Should there be castor washers (shims) packing in the front upper wishbone joints (aft joint of the shock)? Or is that the design?

Do i need to remove the wheel arch liner to gain access to the front wishbone bolt

I sprayed all suspension nuts/bolts and retired for the night.

Day 2

I decided to start on the front nearside.

First off I removed the nut retaining the brake pipe clip.

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Then removed the brake caliper with an 8mm allen socket.

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...and using a cable tie secured it to the anti-roll bar for now. I will be removing the anti-roll bar later to clean and replace the bushes and give it the anti rust treatment

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I then removed the brake disc (no further screws/bolts holding it on)

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I then removed the upper strut support bolts using a 17mm socket and 17mm spanner

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....and then the lower one

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Removed the shock assembly

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I then loosened off the front tie rod end bolt using a 17mm spanner and lubricated the dust cover (these were replaced last year and will be reused)...

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before freeing off the joint using the joint splitter.

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I loosened off the nut holding the upper wishbone to the Hub using a 19mm spanner (wishbone kept in place for now)

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...and then the same with the bottom using a 19mm spanner (wishbone kept in place for now)

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I then tried to loosen/remove the drop link but the threaded bar just rotated with the nut..

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So in summary:

Can the upper wishbone bolts be removed without removing the wheel arch liner?
Should there be any castor shims in the aft upper wishbone joint or is that the design to allow movement/deflection in that area?
How can i remove the droplink to the anti roll bar (I could try putting another nut on it and using 2 spanners)?
Last edited by dris on Wed Jan 21, 2015 12:53 pm, edited 1 time in total.

seriouslylotus
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Re: Suspension Refresh

Post by seriouslylotus » Fri Jan 16, 2015 7:40 pm

I have those Nitrons on stock for immediate delivery!!
I can also offer a suspension refresh kit at special rate for a fellow exiger.
Refresh kits include
8 OEM ball joints, 2 TRE, 2 ARB Droplinks, Full set of suspension bushes and a suspension nut and bolt set
http://www.seriouslylotus.com/catalogse ... t/?q=ntr46
http://www.seriouslylotus.com/suspension-refresh-kit (special price to be added later if you would like?)
You may also need
http://www.seriouslylotus.com/steering- ... h-bolt-kit

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jonnyfox
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Re: Suspension Refresh

Post by jonnyfox » Fri Jan 16, 2015 9:54 pm

Dave I'll be ordering all that and some other stuff next week. Dris doing the same to start with, getting the clams and wheel arch liners off kept my Dremmel busy mate.

Not the Nitrons lol, I'm an Ohlins man.......like Benj :-)
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Benja
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Re: Suspension Refresh

Post by Benja » Fri Jan 16, 2015 10:13 pm

jonnyfox wrote: Not the Nitrons lol, I'm an Ohlins man.......like Benj :-)
Can't wait to get the car out and have a go with them on circuit bud. Sat 21/2 at Donny, I think Sean is gonna come and give me a hand hopefully..would be great to see you.

Great build thread Dris. You're in for a treat when it's all back together it will be like a new car :cool:

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jonnyfox
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Re: Suspension Refresh

Post by jonnyfox » Fri Jan 16, 2015 10:23 pm

May make that Ben....
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JDS
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Re: Suspension Refresh

Post by JDS » Fri Jan 16, 2015 11:18 pm

Can the upper wishbone bolts be removed without removing the wheel arch liner?

Yes they can, you need to lever it slightly out the way and can be more fiddly than just removing it. Depends on how many of the fixings are seized though!

Should there be any castor shims in the aft upper wishbone joint or is that the design to allow movement/deflection in that area?

There are some castor shims in there. They are normal sized washers though, so it looks like there aren't any. When you take the wishbones out they will fall out on the floor, stay in the box section or be stuck to the wishbone bush. When you rebuild it all, fit the larger washers to front and rear of the wishbone, or superglue the small washers together to avoid lots of swearing.

How can i remove the droplink to the anti roll bar (I could try putting another nut on it and using 2 spanners)?

There is a pair of flats on the other side of the anti roll bar that you can hold the threaded part with. There is no guarantee that this will be of any use as the thread is a finer pitch than standard and rusts quite happily. Be prepared to cut them off and replace them.

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jonnyfox
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Re: Suspension Refresh

Post by jonnyfox » Fri Jan 16, 2015 11:41 pm

John just so you know, I'm going to take everything apart and YOU owe yourself to build it back up again......know what I mean lol.
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dris
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Re: Suspension Refresh

Post by dris » Sat Jan 17, 2015 4:10 am

seriouslylotus wrote:I have those Nitrons on stock for immediate delivery!!
I can also offer a suspension refresh kit at special rate for a fellow exiger.
Refresh kits include
8 OEM ball joints, 2 TRE, 2 ARB Droplinks, Full set of suspension bushes and a suspension nut and bolt set
http://www.seriouslylotus.com/catalogse ... t/?q=ntr46
http://www.seriouslylotus.com/suspension-refresh-kit (special price to be added later if you would like?)
You may also need
http://www.seriouslylotus.com/steering- ... h-bolt-kit
Cheers Dave, I already have everything on order but if I need anything I'll give you a shout.
JDS wrote:Can the upper wishbone bolts be removed without removing the wheel arch liner?

Yes they can, you need to lever it slightly out the way and can be more fiddly than just removing it. Depends on how many of the fixings are seized though!

Should there be any castor shims in the aft upper wishbone joint or is that the design to allow movement/deflection in that area?

There are some castor shims in there. They are normal sized washers though, so it looks like there aren't any. When you take the wishbones out they will fall out on the floor, stay in the box section or be stuck to the wishbone bush. When you rebuild it all, fit the larger washers to front and rear of the wishbone, or superglue the small washers together to avoid lots of swearing.

How can i remove the droplink to the anti roll bar (I could try putting another nut on it and using 2 spanners)?

There is a pair of flats on the other side of the anti roll bar that you can hold the threaded part with. There is no guarantee that this will be of any use as the thread is a finer pitch than standard and rusts quite happily. Be prepared to cut them off and replace them.
Cheers for the tips, I'll try the fasteners on the wheel arch to remove it first, didn't look like too much flex in the linner to work with.

Elise111S
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Re: Suspension Refresh

Post by Elise111S » Sat Jan 17, 2015 7:45 am

This is good Dris, I'll be doing this with mine soon. I'd like to make Anglesey too!

BACON
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Re: Suspension Refresh

Post by BACON » Sat Jan 17, 2015 10:48 am

I'm in the middle of doing this too. My wishbones are at the zinc platers having the yellow zinc and de-embrittlement treatment. I was going to go with a clear coat of por-15 as well but have just bought some epoxy mastic chassis paint from these guys http://www.rust.co.uk

Also going the bearing route too. I went for the elise-shop kit which arrived last week. I see elise parts now do a kit as well.

Keep up the good work and write up :)

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