Suspension refurb finally done! Whoohoo!

[450knotOffice]

After four long weeks while the car sat on Jack stands in my garage and was worked on by yours truly seemingly every available minute, I am essentially done with my suspension refurbishment (and many other jobs that needed to be done). All that's needed now is an alignment and corner balance.

I took her out on the road tonight for her first very short test drive with the new suspension and was amazed at the fact that she drove pretty well even though her alignment is probably way off - I know nothing about how to do even a basic alignment so I'm leaving that to my mechanic, of course.

I was quite pleased with the suspension. It was not nearly as harsh as I had expected it would be. It was tight and responsive, but not harsh.

Bushings were replaced front and rear. No, not the polybronze, as much as I wanted them - maybe in a couple of years. I ended up with the polygraphite bushings, sized them to fit, and used about the best quality specialized bushing grease on the market.

Torsion bars were upgraded to 22's and 28's. The Boges, front and rear, were replaced with Bilstein Sports and both front struts were replaced with good used one's from a friend. Turbo tie rods were installed, along with new ball joints. The steering shaft support bearing in the smuggler's box was basically gone, so it was replaced.

One of my camber plates was replaced. A Rennline strut brace was installed. The brake pads were replaced with Metalmasters and the brake system flushed. One of my oil return tubes was leaking badly so it was replaced. The car was lowered slightly. And finally, my battery was replaced.

Oh yes, and while I was at it, I replaced my floor mats with some really nice ones with the Porsche crest on each one.

I have to thank all of you that offered your advice and wisdom. Without the Pelican forum I would never have considered such an undertaking. It was a fun, challenging, sometimes maddening, but ultimately a very gratifying experience.

I can't wait to get it out on a twisty road!!

[Carrera3.5L]

Way to go Scott!

Ralph

[BlueSideUp]

Congrats, that sounds like a lot of work!

Any tips on where I can pick up some of that high quality grease?

[kg911]

Hey Scott, I think its time for another run through Ortega. Looking forward to seeing all the work done.

Kelly

[450knotOffice]

I agree, Kelly. The car is a little lower now than it was last time you saw it - more like yours now.

BlueSideUp, the bushing grease I used is made by Energy Suspension, but they don't sell to the public. You have to get their grease through auto stores or you can order some online at http://www.energysuspensionparts.com/home/

They sell the stuff. It's called Formula 5 pre-lube and it's specially formulated for bushings and their unique needs.

[TerryH]

Way to go, Scott. Nothing like that feeling of accomplishment when a plan comes together. I'll probably do the tie-rod kit later this summer and most of what you did next year.

So... without trying to get too nosey, how much did the whole shabang cost you and was it about what you had estimated before starting? Labor hours? Biggest surprise?

[450knotOffice]

Terry,

I spent a couple thousand + on the parts and related supplies, which was more than I had expected. Some expenses came up without warning when I found damaged items that needed attention. Also, some of the things done were not related to suspension at all, like the oil return tube.

As for labor hours...I'm not sure really. I probably spent 15+ days actually working on it, so maybe 100 + hours. I have to qualify that by mentioning that I'd never tried anything like this before so it was a learn as you go process and I took my time and worked methodically. Also, I'm including time spent on this forum researching issues.

[Nine9six]

Scott,
I want to thank you again for publication on the suspension job! Very informative and well documented.
Thanks!
Paul

[fastpat]

Hearty congrats, Scott. I'm at the beginning of suspension upgrades here, and in fact will shortly walk out to do the anti-bump steer kit install, and maybe lower the rear suspension if I can do it with the adjustment bolts, another day if I have to re-index the torsion bars.

My low mileage makes this difficult. Most would disagree with that statement, but here's why. Virtually none of my suspension is worn out, it only has 25,800 miles on it. The problem is that some of it has simply gotten old and dried out, and I have to sort out what's bad and what's good. If it's not broken, I won't fix it unless it's with an improved part like the Poly/bronze components.

There is one great thing about a low mileage car, though, few if any of the nuts are frozen or rusted, and that's a big help on a suspension project.

Again, good work.

[450knotOffice]

Paul and Pat,

Thanks. The rear end turned out to be pretty easy and straightforward. I didn't really feel like I could add anything to this forum that hasn't been brought to light before so I just sort of stopped updating the other thread.

I spent half the day yesterday re-indexing the springplates. I got pretty good at it. I'd say that I got to the point where I could go from the car being on the ground, to re-indexing one side, to the car being back on the ground again in about 30 to 40 minutes.

Pat, I hear ya about the fasteners not being rusted but my car lived in Florida most of its life so the front torsion bars were rusted in pretty tight. Other than that, most of my fasteners were tight but not rusted.

Good luck.

[84porsche]

Scott,

I was looking for an update on the other thread and just found this one. I am surprised I missed it. I spent the weekend in the garage and the shed cleaning my tools and other stuff to see what I have. Glad to hear that she is done. Can't wait to see the end result. I bought new rear light seals from Pelican after I pulled off my tail lights this weekend and noticed a lot of dirt was sitting inside.

Chris

[450knotOffice]

Thanks, Chris.

Glad to hear you're starting to open up your car and take a look inside. If you ever want any help, give me a call. I'd be glad to help out.

As for the dirt...amazing, isn't it?! I've found dirt and gravel in the strangest places. Makes me think the car went off road at some point in its life

The car is going to the shop on Friday morning for an alignment and corner balance. They say it'll be done by that afternoon.

[motion]

That thing should be tearing up Ortega!

Where are you taking it for the alignment? I've had an excellent experience with Darren at West End in Torrance. Highly recommended, although I'm sure there are others more local that are excellent also.

[450knotOffice]

It's going into Hergesheimer on Friday morning - by appointment. Laura says it'll be ready by Friday afternoon. I sure hope so because I don't want that car sitting there over the weekend. It needs to be driven.

[84porsche]

Scott,

Are you going to the new member PCA bbq on Saturday? I am sure you have gotten tons of emails regarding it.

Chris

[azasadny]

Scott,
Congratulations on a job well done!!

[450knotOffice]

The car was delivered to Hergesheimer's this morning at 8 AM on the dot for the alignment and corner balance. Their resident expert, Jim, worked on her all day. Very few people can work alignment and corner balance magic like Jim can. Well, he did it again.

All I can say is WOW!! I know about alignment but I know nothing about how to set it up, especially in back. So when I gave it to him, it basically had all four wheels set at random alignment settings. He was starting from scratch, other than ride height. After working on the car literally ALL day, he had the car about as balanced as possible and the alignment just the way I wanted it.

Here's what he got:

LF - 501
RF - 504
LR -814
RR - 814

Camber Front - 1 3/8 degrees
Camber Rear - 1 1/4 degrees

The car drives SWEET!! It's stiff but not harsh at all. I like it.

[TerryH]

When you get rid of the glitz and glamour, and paint and bling, and pomp and circumstance.... when get down to the meat and potatoes.... you get to the chassis and suspension.

It doesn't make your ride look any prettier or sound any meaner, but it does make your car safer on a solid platform. You can put your trust in the thought your car is going to obey your input and not have mind of it's own through worn parts. It's the foundation that all else is stacked upon. It is also one of the most neglected areas of most cars and it's on my list of things to do....

[450knotOffice]

You are so right, Terry, which is why I toiled for a month straight on my car replacing basically everything - most of which was worn out - and spent well over a couple thousand plus on.

The car feels so tight now. Little rattles and shimmies that I used to have are gone now.

[EdT82SC]

It's been great fun following your progress. I can't wait to do mine now. So how much does Hergesheimer's charge for an alignment and corner balance?