Build Your Own Koni Coilovers

[DG-FNR]

Not so long ago, I was building and (attempting) to sell coilover kits for 2G DSMs, based on real shocks, not the cheap crap that seems to keep coming up.

But shortly thereafter, I decided to go back to the Army, and those shocks came off the market.

Now I'm about to deploy, and the technology for duplicating those parts should not be lost... just in case the worst happens.

So I've posted the drawings to Autocross.dsm.org - Build Your Own Konis (which is supposed to resolve to Autocross.dsm.org - Build Your Own Konis in case Todd has accidentally reset the DNS back to the old Wincom site)

I'm giving permission for people to use this for PERSONAL USE ONLY - go ahead and make yourself a set, but DO NOT start making these for other people for profit.

The ONLY vendor I will allow to make these for open sale is Magnus Motorsports - if he wants to, that is.

Remember - clicking the ads helps pay the bandwidth bill.

DG

 

[RipperXX]

Got any usefull knowlage for us 1G guys?



Also I am in the Army here in Iraq...again so maybe I will see you here man. PM me what FOB/COB/PB etc. you will be at.

 

[DG-FNR]

Got any usefull knowlage for us 1G guys?



Also I am in the Army here in Iraq...again so maybe I will see you here man. PM me what FOB/COB/PB etc. you will be at.

Wrong portion of Asia. I'm going to the other side of Iran.

I might have some 1G prototype drawings... lemme check.

DG

 

[DG-FNR]

Nope, nothing for 1Gs - sorry.

DG

 

[RipperXX]

damn on both parts . Thanks anyway.

 

[Ceddy]

Good info. Thanks for sharing.

 

[D_Eclipse9916]

THANK YOU so much for sharing this. I wish I had the tools/way to build those upper mounts and standoffs. I really wish you could have sold more of those setups, but it was not yet the time for dsms to become more popular as they are starting to with the road race crowd.

I always wanted your setup but I was broke (still broke ). You were on the short list, alas now we have to deal with regular coilovers and not quite so ideal suspension theories that some people have made up on these forums. Thanks for all your hard work!

 

[DG-FNR]

Take the drawings to your local machine shop and get a quote.

A typical high school metal shop has the tools you need to build this stuff. For a modern machine shop, it's trivial.

DG

 

[Freerevving]

just curious if the cost comes close to $400 without the Koni's.... You could use the G.C. kit

 

[DG-FNR]

You can use the GC sleeves, but NOT the upper mounts.

DG

 

[underBoostAWD]

Thanks Dennis,
I put together a set almost two years ago now, based mostly on your design.
They work great!
My results this year reflect the improvement from more predictable handling.

 

[housegsx]

When the time comes that I can afford to retire my old Tein basics, I'll be going this route. Thanks for sharing everything.

 

[99gst_racer]

Thanks for the contribution, Dennis.

 

[Freerevving]

You can use the GC sleeves, but NOT the upper mounts.

DG

Oh I get it... 2g... my bad...
So GC doesn't make the top mounts for 2g...

 

[DG-FNR]

They do; they suck.

Read the webpage.

DG

 

[maximumbob]

Thanks for taking the time to make available this and all the other information for everyone. It's rare in this day and age to find quality information like this in a single source. I appreciate your efforts.

 

[turbosax2]

Thanks for the good info DG.



I was curious about how costly this setup would be, so I threw together a quick price list.

(2) Koni Yellow Shocks (Front) - $155.00 (extremepsi)
(2) Koni Yellow Shocks (Rear) - $155.00 (extremepsi)
(4) Hypercoil springs, 2.25" x 8" - $75.00 (hypercoil)
(4) Hypercoil helper springs, 2.25" - $19.95 (hypercoil)
(4) Aurora PNB-12T spherical bearings - $34.70 (hrpworld)
(4) Torrington bearings, 2 races per bearing - $20.55 (performance shock, inc.)
(4) Koni coilover sleeves 80.0000.1 - $36.76 (sport compact warehouse)
Total = $1367.84

(4) Inside snap ring - ?
(4) Upper mount plates - ?
(4) Upper standoff - ?
(4) Lower standoff - ?
Hardware - ?
Plus other machining / coating costs

 

[D_Eclipse9916]

Wow holy shit just saw your calculator. I am going to have to figure out those rates. Unless you have a suggsetion for a mostly stock except RM sway bars (maybe go back to stock) spring rates?

 

[Freerevving]

They do; they suck.

Read the webpage.

DG

Couldn't find anything on the webpage, maybe something wrong with the server.. is it because the tops don't pivot? I'm confused

 

[DG-FNR]

From the web page:

There is a commonly availible aftermarket upper mount, but the spring rests dirrectly on the underside of the mount plate, and that is a HUGE no-no. The spring needs to be able to pivot to be able to remain coaxial to the shock shaft without bending

DG

 

[awddsm95]

I have a set completly made other than cutting the new groves into the shocks. I also have not purchased the springs, but have everything else. I am curious about ride height. With this set up, how can you adjust the ride height?

 

[housegsx]

I am curious about ride height. With this set up, how can you adjust the ride height?

The Koni coilover sleeves allow you to adjust ride height.

 

[awddsm95]

They do if you dont have preload on you springs in full droop. I guess that is what the helper springs are for. But at that point, its a bit more difficult to set your corner weights and maintain the exact same ride height from wheel to wheel. Am I thinking about this correctly?

 

[No_Skillz]

In regards to your machining diagrams what units are the measurements in?

 

[awddsm95]

They are all in inches