30 Year suspension overhaul, street spec

[TheSt|G]

Suspension Overhaul

Big update, and one that has been brewing since I picked up the car. Being that it is 30 years old, most of the suspension can safely be assumed to be worn out. While I was ok with the sloppy handling while getting to know the rest of the car, the fear I could break a ball joint and careen into a tree wasn't particularly reassuring when beating on the car.


So with that in mind, I replaced:

Front shocks
Rear shocks
20mm front torsion bars
26mm rear torsion bars
Ball joints
A-Arm bushings front
A-Arm bushings rear
Front sway bar bushings
Rear sway bar bushings
Rear sway bar end links
Rear spring plate bushings
Rear trailing arm bushings
Front shock mounts
Rear shock mounts
Torsion bar seals
Powdercoated all the front suspension parts/rear sway bar
Fresh hardware all around


When I got all of that in, I had it corner balanced, aligned, and lowered to the Euro ride height. With a full tank of gas she weighed in at 2550lbs, not bad for a street spec 911.



Getting prepped with boxes to sort all of the parts coming off and up she goes:





Wheel off and front suspension disassembled aside from the strut assembly:







Front A-Arms out, which look to be in pretty good shape:





Bushings on the A-Arms were completely hosed though(should be an even circle around the arm):





But it's nothing that the propane torch can't fix:





Sadly, those shot bushings were causing the torsion bars to contact the contact the A-Arms, where they rubbed and caused themselves to rust, requiring replacement. This is why we preventatively maintain!





Most of the hardware, like these sway bar brackets, is in pretty good shape for some mild restoration in the form of sand blasting and powdercoating:

[TheSt|G]

All of the front suspension parts and the rear sway bar assembled and ready to be driven to my powdercoater:







About a week later, I got everything back. They did an absolutely spectacular job, blasting each part, getting a nice even coat, and avoiding any areas that they should like the torsion bar spindles in the A-Arm or the threads on the sway bar brackets. Total cost per part for blasting and coating was $4.60.

[TheSt|G]

With that taken care of, it was time to reassemble the front end. The parts catalogue:










The A-Arm bushings and their respective collars have to be assembled at specific angles to provide the proper mounting position for reassembly. It's any interesting game of back and forth as they want to slip off as you rotate them. Nailed it:





Everything getting buttoned up in the front, and yes, I put the lock pin and plate in the ball joint after installing it:

[TheSt|G]

And here's where I fail, I forgot to take pictures of the rest of the project. The new torsion bar end levers and torsion bars took long enough to come in that I was a bit focused when everything finally arrived for me to put back together.


First shots during the maiden voyage of the new height and such. She feels absolutely phenomenal:

[tirwin]

Great work!

I just recently replaced my rear suspension bits. I was stunned at how much is transformed the car. Can't wait to do the front.

[BFT3.2]

Great job, congrats!

Between last fall and this spring I did the exact refresh on my '88 plus rebuilt the steering rack, added turbo tie-rods, used Rebel Racing bushings front & rear, Elephant offset camber plates and went 22/30 on the torsion bars to make her firmer for the track (shocks re-valved to new spring rate). Spent 100+ hours doing it but what a incredible transformation!

That is a good weight you have there. I removed EVERY bit of the AC system, replaced battery with the 15lb Odyssey and came in at 2708 with a half tank and no spare tire. G50 showing her weight. The new EM 9" Fuchs & 245's prob didnt help.

Beautiful car, enjoy the summer!

[Tippy]

$4.60?

[TheSt|G]

Originally Posted by BFT3.2

Great job, congrats!

Between last fall and this spring I did the exact refresh on my '88 plus rebuilt the steering rack, added turbo tie-rods, used Rebel Racing bushings front & rear, Elephant offset camber plates and went 22/30 on the torsion bars to make her firmer for the track (shocks re-valved to new spring rate). Spent 100+ hours doing it but what a incredible transformation!

That is a good weight you have there. I removed EVERY bit of the AC system, replaced battery with the 15lb Odyssey and came in at 2708 with a half tank and no spare tire. G50 showing her weight. The new EM 9" Fuchs & 245's prob didnt help.

Beautiful car, enjoy the summer!

To be fair, I've also ditched all of my AC except the lines and fender unit. My battery is also a lighter Odyssey in the smugglers box, and I'm running Recaro Speed S seats.

Originally Posted by Tippy

$4.60?

Yes, per part. They are my absurdly well priced blasters/powdercoaters.

[BFT3.2]

Originally Posted by TheSt|G

To be fair, I've also ditched all of my AC except the lines and fender unit. My battery is also a lighter Odyssey in the smugglers box, and I'm running Recaro Speed S seats.

Ahh.. Ok, that makes me feel a little better.

[Tippy]

Per part sounds great! Nice.

[TheSt|G]

Originally Posted by Tippy

Per part sounds great! Nice.

Yup, they do tons of stuff for me. Just recently had them hit some garage chair frames I made from pipe and the front seats from an 80s Merc. I probably wouldn't use them for something like the fan, but for everything else you can't go wrong.


I wasn't the only air cooled customer judging by this box I saw when I dropped the parts off: