View Full Version : Bent coilover spring
Hey guys,
Looking for some advice here:
I'm putting together my red Series 30 Koni shocks from the complete kit with IRS. The front assembly went together without a problem, as did the first of the rears. But my final shock assembly has what appears to be a defective spring. The spring hat won't fit into the opening because the tip of the spring is bent inward slightly, or maybe the final coil is bent out of true round altogether.
As a workaround, I tried flipping the spring 'upside down' (I don't think the direction matters except for the lettering stamped on it). Likewise, the spring seat won't fit into the opening either.
Here are pictures of the issue:
https://thefactoryfiveforum.com/attachment.php?attachmentid=140552&d=1610314661
https://thefactoryfiveforum.com/attachment.php?attachmentid=140551&d=1610314651
I could try to spread the bent tip using a DIY spreader tool (an all thread bolt plus a couple washers and nuts), but wonder how advisable it is to tamper with a mission-critical part like this. Any advice on how to proceed?
First, I'd contact FFR to ask for a replacement. If that doesn't work for you, I'd simply grind that end of the last coil until the coil properly seats. Use a bit of POR-15 to touch up the powdercoat.
Thanks guys, I’ll reach out to FFR.
Rdone585
01-10-2021, 08:51 PM
You will most likely heat up the metal of the spring by grinding it. The properties of the spring could change if not done properly. I would opt to get a replacement.
RBachman
01-10-2021, 08:57 PM
Are they using cheap chinese springs?
rich grsc
01-10-2021, 11:35 PM
You will most likely heat up the metal of the spring by grinding it. The properties of the spring could change if not done properly. I would opt to get a replacement.
Grinding on the spring isn't going to change anything, it won't even get too hot to touch. Where do you come up with this stuff?
Be careful grinding on springs as striations and discontinuities can cause stress risers that may eventually lead to failure. Trying to trim away part of the end coil can easily lead to nicking the adjacent coil causing a stress riser in it.
The coil spring was defective when received so FFR should replace it -- problem solved! Sending back a defective part for a replacement may cost some time, a bit of delay, and shipping expense but you will end up with a correct and defect free part in the end.
edwardb
01-11-2021, 06:45 AM
Assuming this is from a (somewhat...) recently received kit? Just call FFR. I'm positive they will send you a new one. And almost as positive they won't want the defective one back. I'd bet their cost on those is pretty low so no point in shipping it. So no hassle from your side at all other than a slightly delay. I personally wouldn't have a problem with trimming the end just slightly, being careful obviously to not overheat or damage any other coils. Wouldn't be hard and wouldn't affect how it works. But for a new part that's defective, they will replace it and the best way forward.
ydousurf
01-11-2021, 09:27 AM
Both of my rear shocks came this way too, Rook. It's clear that the VENDOR is printing the (weight - lbs#) marking with the shocks being upside down, since they seem to fit only one way. The (the vendor) either needs a redesign on the specs of the shock so that they'll fit both-ways, or they need better quality control.
As for my fix, I took a solid piece of advice which is summed up in the quote from Paul (edwardb) --- "It's absolutely a custom car! There are people who buy these kits and think it's like a snap together model kit and it's not, it's absolutely a custom car that you make just the way you want."
This is the video link --- https://www.youtube.com/watch?v=gCBLH-mr7ME
Definitely watch the vid if you haven't yet, since it's done so well, as are all of his builds! I've used that advice and thinking as I'm going through this entire build process...
And Paul is so, so right! These kits are going to take some finesse, some modification(s) and even some persuasion (think big hammer) sometimes to make parts go together. With that said... I just filed mine down (hand file) that is and a little bit of black paint - waaalaaa! Nobody knows, well, now you all do! Anyway, just sharing my hurdle. You could request new one's, but for me, I figure it wasn't that big of a deal. It won't affect the performance of the shock whatsoever. They just needed a little massaging to make them fit! Happy building!
Dj
Edwardb: Yes, I received the kit last month. I got in touch with FFR this morning and a new one is on the way. Thanks again for the input!
How Eibach makes their springs:
https://www.youtube.com/watch?v=6ZMuMvpgKFs
If they can grind them ...
mabbott74
05-19-2021, 09:21 PM
I just received my red Koni's today and both springs are smaller on one end so they won't fit over the hat. I guess I will reach out to FFR tomorrow and see what they recommend. Glad you got yours sorted.
CraigS
05-20-2021, 06:43 AM
I would have ground it if it were mine but now it's looking like a bad manufacturing run isn't it?
GTBradley
05-20-2021, 09:17 AM
I had this on a spring back in early 2019 and I hit it with a file.
Avalanche325
05-20-2021, 01:45 PM
I had this on a spring back in early 2019 and I hit it with a file.
.....and at that very moment a black hole opened up on the other side of the galaxy.
GTBradley
05-20-2021, 01:53 PM
.....and at that very moment a black hole opened up on the other side of the galaxy.
Why don’t I see these things before you?
AC Bill
05-20-2021, 03:28 PM
So much for quality control..Blame it on Covid..
BrewCityCobra
05-21-2021, 08:41 AM
Both of my rear shocks came this way too, Rook. It's clear that the VENDOR is printing the (weight - lbs#) marking with the shocks being upside down, since they seem to fit only one way. The (the vendor) either needs a redesign on the specs of the shock so that they'll fit both-ways, or they need better quality control.
As for my fix, I took a solid piece of advice which is summed up in the quote from Paul (edwardb) --- "It's absolutely a custom car! There are people who buy these kits and think it's like a snap together model kit and it's not, it's absolutely a custom car that you make just the way you want."
This is the video link --- https://www.youtube.com/watch?v=gCBLH-mr7ME
Definitely watch the vid if you haven't yet, since it's done so well, as are all of his builds! I've used that advice and thinking as I'm going through this entire build process...
And Paul is so, so right! These kits are going to take some finesse, some modification(s) and even some persuasion (think big hammer) sometimes to make parts go together. With that said... I just filed mine down (hand file) that is and a little bit of black paint - waaalaaa! Nobody knows, well, now you all do! Anyway, just sharing my hurdle. You could request new one's, but for me, I figure it wasn't that big of a deal. It won't affect the performance of the shock whatsoever. They just needed a little massaging to make them fit! Happy building!
Dj
I received my kit back in November and had the same problem on the rear springs. They fit when I flipped them over so I just ran with it - OCD on the printed text be damned.
mabbott74
05-21-2021, 07:36 PM
I received my kit back in November and had the same problem on the rear springs. They fit when I flipped them over so I just ran with it - OCD on the printed text be damned.
I could handle them flipped but the ones I got wouldn't work that way either. The hats/collars seem to be the same diameter on what I received. I wish it were that easy. We'll see what FFR decides to do.
tonywy
05-22-2021, 06:10 AM
Check out Hyperco for springs. I just bought a set, they fit perfect and appear to be high quality.
https://www.hypercoils.com/markets/
mabbott74
05-26-2021, 11:40 AM
Received my replacement springs today and unfortunately they have the same issue. One side fits fine and the other is too small. I suggested that someone in the warehouse test fit a spring hat on each end but apparently they didn't. I'm waiting on a return call from FFR. I'm tempted to take a couple quick measurements of the coilover, return them and order something elsewhere. In the grand scheme of things if this is the worst thing I have to deal with this week I'm doing pretty good.
CraigS
05-27-2021, 06:19 AM
I expect FFR will get you some good springs pretty soon. If you decide to get others get just springs. The Koni shocks that FFR provides were engineered by them and Koni for these cars so there is some advantage of them vs others. I like the QA-1 high travel springs. You can order from Summit. 2.5 inch ID, same length and rate as your existing springs.
Just grind the offending defect -- ain't gonna hurt the spring for the short amount of time you'll be heating that very small portion. I understand the desire to get correctly manufactured parts, but wouldn't delay my build over this issue.
rich grsc
05-27-2021, 01:56 PM
Just grind the offending defect -- ain't gonna hurt the spring for the short amount of time you'll be heating that very small portion. I understand the desire to get correctly manufactured parts, but wouldn't delay my build over this issue.
Agree. I do not get where people get the idea that grinding can possibly heat the metal enough to change the temper. If it could, how would they powder coat them (400*)? You could cut completely through the springs with a cutoff wheel and not change the temper.
mabbott74
05-28-2021, 10:40 PM
Update - After speaking with FFR tech I was instructed to apply a 'small amount of force' to seat the hat on the spring. Since my full body weight failed to motivate the offending part I escalated the situation. I took 'small' to mean the application of two ratcheting bar clamps which did the trick. I put the hat on the tight side so that the spring seat would not bind when adjusted. I did have to remove the rod end to install the spring and hat because that seemed like a better option than separating them. I guess I will ship the extra springs back next week.
FFinisher
05-29-2021, 07:44 AM
Grinding on the spring isn't going to change anything, it won't even get too hot to touch. Where do you come up with this stuff?
You always say what I am thinking.
I can’t count how many of those I have touched up.
Wonder if anyone’s as ever had to clean up the powder coat on their chassis or other parts?
Wonder if that changes the properties if the metal too.
Kleiner- yes I checked the firing order!
rich grsc
05-29-2021, 11:18 AM
You always say what I am thinking.
I can’t count how many of those I have touched up.
Wonder if anyone’s as ever had to clean up the powder coat on their chassis or other parts?
Wonder if that changes the properties if the metal too.
Kleiner- yes I checked the firing order!
Oh good lord don't grind the PC off the frame, the metal will collapse. :eek::rolleyes:;)