well, after always wanting to go lower and not wanting to do air-bags, I decided to make my own coilovers.

These are KYB-AGX struts with 12" 350# springs.

I used a stock mount, the collar inside it and front sway bar end links. I had to buy a few parts from Summit Racing: thrust bearings, springs, sleeve, nut and top hats. I had tried to use Rancho shock boots as dust boots but they were just a little too big to fit inside the spring I saw someone on CGP mention a miata steering boot, might try that later on.

So I started with cutting apart the mount. Used an air hacksaw to cut away the rubber and the metal collar inside the mount. Then took a cutoff wheel and cut the metal off the bottom. Once that was done I welded the bump cup to the mount though I don't have a picture of just that.





I then took a grinder to the collar that is in the stock mount. I grinded the top so it would fit inside the top hat. This takes the play out of the top hat and the strut and makes it move up/down with the strut. Because the bore of the hole in the top hat is bigger than the strut shaft I had to use this. I also cut the collar in half to make it shorter for more strut travel but don't have a picture of it after I cut it.


Here is the collar in the top hat.


After that the top mount is done. I then moved on to the strut. Using a cut off wheel, air hacksaw, a spray bottle of water and a bucket of water I worked at removing the spring perch. I used the cut off wheel first and slowly worked around the perch just above the weld. I was spraying the strut with water to cool it down and then dipping it in the bucket every so often. Would suck to ruin a good strut! Once the perch is off I had to grind the weld down to fit the sleeve over the strut. Also, for alignment issues you may want to ream the holes out on the bottom of the strut to give you more movement. Thanks to Weirdo for that tip.


After that, pound the sleeve on.

Now on to the bushing stack up. I used stock sway bar endlinks. I cut the top off of them so one side was perfectly flat and left the other side untouched.
If you look at the picture of them below, the sides I cut off are where the two bushings touch each other. You need these since the strut has to have some movement. One goes on each side of the mount.
I also used the metal washers that came with them. I drilled both the rubber bushings and the washers larger to fit over the strut shaft which you can see in a picture later on.


After that you're ready to assemble.
Struts

Sleeve, nut, washer, bearing, washer, spring

close up of washers and thrust bearing

here I attempted to get a picture of the ground down collar and top hat while it was on

Then put on the collar and the top hat

After the top hat is on, the first sway bar bushing goes on. You can see it sandwiched between the top hat and mount.

Then on goes the mount, the second sway bar bushing, the sway bar washer and then finally the strut nut.


And admire!
Can go maybe 1/8" lower


In these pics it can still go an 1" to 1.5" lower




-- Fri Sep 17, 2010 9:03 am --

After requests for more pictures from another forum I took these.

Showing everything used for this and in the order they go from left to right.
Here is a link to the pic below
http://i278.photobucket.com/albums/kk110/r-s-hutchinson/DSC00671.jpg


Here is pics of everything as I put it on.
Washer, then thrust bearing (took it with top washer off so you could see the bearing)



Then next washer


Then spring


Then collar




Here are some pics to show how the collar goes in the top hat:
Top of both

Side

Bottom

Now the collar inside the top hat (looking at bottom)


Then top hat


Here are the sway bar end link bushings I cut up to show which side I cut off. I also had to bore the holes out to fit over the strut shaft. Big PITA to drill this rubber.



Then mount. You can see the bushing between the top hat and mount in the last two




Then second bushing


Then sway bar end link washer


Then finally the strut nut. (not tight in this picture, I tightened it enough to squish the bushing to fill out the bump cup, had maybe 5 threads showing above the strut nut when all tightened)


And the whole thing


Installed:

SICK

Great work and thanks for the pictures. Too much work for me most likely, so I plan to get the ZZP's this year sometime.

Great stance.

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04 GTT - Retired
Best ET 13.016
Best Trap 115.56 MPH

You just made my week!!!!!!!!! Awesome job. I have to ask though, how much was the grand total?

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Dubs:00 VW GTI VR6, Low and Slow 91 VW GTI 8v, Shave the Bay!! 91 VW Cabriolet 8v, bitch Basket
GP's:04 GP GT, Past now G-Ma's Girlfriend's 97 GP GT, "Project Pink Power"

Total costs - $200 for springs, sleeves, nut and top hat. $30 for bearings I believe. Struts - w/e, I already had them, not sure how much they are new. Sway bar end links - had them already but they are like $10. Mounts - used my stock ones

So under $300 for new parts, then just add your choice of struts.

Nice, that's a darn good price.

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Dubs:00 VW GTI VR6, Low and Slow 91 VW GTI 8v, Shave the Bay!! 91 VW Cabriolet 8v, bitch Basket
GP's:04 GP GT, Past now G-Ma's Girlfriend's 97 GP GT, "Project Pink Power"

wow, just wow! excellent end-result!
*thumbs up*

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MODS:3.4" ZZP MPS pulley, ZZP PCM, 104 autolite plugs (.054), SS AUTO Headers, 9 in. FWI, home port sc, MORE TBD...
BEST 1/4: 13.80 BEST 1/4 TRAP SPEED: 100.6MPH!!

Wow!! Awesome work man. Looks amazing.

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Holy s*** that is awesome...

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Thanks, it was fun to do. Yes, a little time consuming but well worth it. I was picking burnt rubber (from using a grinder on the stock rubber mount) for a few days afterwards haha.

YOU ARE A GOD!

I was reading all about that thread on clubgp about making your own coilovers, I so want to make my own, but I'm thinking about the ZZP ones as well.

AND OMG YOUR STANCE....thank you for posting those pictures, that is the exact stance I want with my car.

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04 Supercharged American and 01 Turbo Swede

ZZP's/Held's are expensive. They are what, $1300? That's just with the GR2's I think. Another couple hundred for AGX's. Though I do understand that not everyone has access to the same tools.

Nice work

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http://www.cardomain.com/ride/3305211

I want that stance!

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[url=http://www.xboxlc.com/profile/austin0150]

[/url]

$1460 to be exact.

In reality thats not bad, high end coilovers for other cars (JIC coilovers and Tein) can run $2,200. I just want that coilover feeling again, I miss feeling the car ride on rails

In all honesty, I'd have to buy the AGXs, springs, top mounts, springs, etc and I'd probably run into $900 or so into it. so the extra $500 is not so bad.

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04 Supercharged American and 01 Turbo Swede

I wish I had the tools and the mechanical aptitiude to take on such a project!

but for those who do not.....

Are the ZZPs the only GOOD option for coilovers? I thought the GR2s did not last long on a lowered car and the AGXs required 97-03 control arm? and the Monroe coilovers are too soft?? Thanks.

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2009 G8 GT -Sport and Premium Pkgs, Roto-Fab CAI, Cortex 93 Octane Tune, Billet Prototype Catch Can, BMR Front and Rear Sways, BMR RTAs, BMR Rear Cradle Bushings, BMR Steering Rack Bushing, GXP SW......and much more to come.

Nope Intense has had them for a while now
http://intense-racing.com/Merchant2/mer ... ry_Code=BS

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Holy crap I think I love you.... lol j/k but that is f*c*i*g AWESOME.

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2012 Ford Focus SE Sport
2012 MINI Cooper Clubman

I have ADHD and drive a Focus. Ironically.
Although gold dust is precious, when it gets in your eyes, it obstructs your vision.

So would you all recommend the Intense or the ZZP coil over springs?

and do these types of coil over springs set-ups outperform Stock Comp G parts from a handling perspective?

and do they last or would they need replacing after 10K?

Thanks!

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2009 G8 GT -Sport and Premium Pkgs, Roto-Fab CAI, Cortex 93 Octane Tune, Billet Prototype Catch Can, BMR Front and Rear Sways, BMR RTAs, BMR Rear Cradle Bushings, BMR Steering Rack Bushing, GXP SW......and much more to come.

ALL 04+ guys

Remember we would also need lower control arms from a 97-03.

_________________
04 GTT - Retired
Best ET 13.016
Best Trap 115.56 MPH

I'm sure you'll be happy with either ones. Though ZZP sells them, they don't make them, they are a HELD motorsport product. So, if you have issues it may take longer to get to a resolution as they are like a middle man. But I've never dealt with Intense so can't speak for the customer support either.

Yes, coilovers will outperform lowering springs or Comp G springs in every way depending on the spring rate you choose. The beauty of coilovers is that you can use a longer spring since you have an adjustable 'spring perch'. Lowering springs ride like shit because the perch they sit in is a fixed position, so if you want to lower the car, you need a shorter spring. Because the spring is shorter, you need to compensate with a stiffer spring rate, thus the shitty uncomfortable ride. Because of the longer spring with coilovers and adjustable perch you could choose a softer spring rate and still have a lowered stance by lowering the perch.

How long they will last will depend on the spring rate and strut you choose, but they will more than likely last longer than a strut/lowering spring combo.