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SFBMX88 Newbie

SFBMX88

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So far, the fronts are done....

 

Starting with the parts:

 

Refreshed my Artinist coilover(70mm ID springs) set with some longer Tein springs I found at 949racing http://949racing.com/teinracesprings.aspx

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09818.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09821.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09823.jpg

 

1988/1989 Toyota Celica FRONT strut housings(MUST BE 88/89 AS EARLIER MODELS HAD FINER THREADS FOR THE GLAND NUTS) - you really only need the upper portion of them above the spring perches, so if youre at the junkyard and have either a big pipe cutter or cordless sawzall, have at it!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09485.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09486.jpg

 

MR2/Celica Alltrac front strut inserts - these include brand new gland nuts for the Celica/MR2

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09483.jpg

 

T3 camber plates

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09470.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09473.jpg

 

Energy Suspension poly bump stops

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00360.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00359.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00358.jpg

 

Some perch rings made from scrap

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09853.jpg

Edited by SFBMX88
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SFBMX88 Newbie

SFBMX88

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Top is a REAR SHP shaft assembly, middle is a front Tokico, bottom is KYB AGX

quite a difference in length! Tokicos also normally use a spacer in the stock housing to take up about 1 inch(more pics on second page).

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09476.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09475.jpg.

 

AGX+Front Celica housing

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09489.jpg

 

AGX pokes out abit from the top

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09488.jpg

 

I was going for a total unloaded stack height(measured from mounting flange to top of camber plate) of about 22.5-23 inches, so I cut about 4 inches off the top off the Starion housing. Save the scraps for later! You never know when you can use them!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09744.jpg

 

Also needed to use an aluminum spacer to take up the rest of the space in the housing, about 1 3/8 inches

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09728.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09745.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09736.jpg

 

See the gap from insert to housing? The AGX inserts have a slightly smaller diameter than regular Starion inserts, and Ill address that in the very next post!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09754.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09735.jpg

 

The reason I use the 88/89 Celica FRONT strut tubes is for the threaded portion. KYB AGX inserts include brand new gland nuts!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09730.jpg

 

Luckily, a friend of mine was in a machine shop class, so he was able to turn them down abit so they fit right into the Starion strut inner diameter

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00617.jpg

 

Outer diameter of machined Celica strut tube:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00621.jpg

 

Inner diameter of Starion housing:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00622.jpg

 

a view from "inside"

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00620.jpg

Edited by SFBMX88
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SFBMX88 Newbie

SFBMX88

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PUT IT ALL TOGETHER!!

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00628.jpg

 

Fits right in! Also, with it being machined the way it is, it goes in STRAIGHT!!!!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00627.jpg

 

A friend of mine owns an exhaust shop, so he helped me out with the welding duties

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00630.jpg

 

Just to be safe, I cut out some sheet metal and stuffed it down the housing to take up the extra space around the insert:

mine was about 5"x10.5"

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00638.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00639.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00643.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00645.jpg

 

Filled them with a bit of oil and locked the gland nuts down:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00647.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00648.jpg

 

TOYOTA GLAND NUTS FTW!!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00649.jpg

 

original artinist coilover spring next to newer, longer Tein spring(had to get longer springs because cutting down the strut housings would put the coilovers out of adjustment range with the old springs)

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00661.jpg

 

LOOK AT THAT SLACK!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00656.jpg

 

I ended up using the same rubber o-rings that were originally included with the coil over kit to reinstall the sleeves

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00657.jpg

 

threw in some new Moog lower ball joints while I was at it

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00667.jpg

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00663.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00674.jpg

 

Still quite a bit of clearance from the wheel! (SHP 8" with 225/50R16)

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00669.jpg

 

 

Before

so much wasted travel in that droop...

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00655.jpg

 

After

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00671.jpg

 

Actually had to bring the height down about 3/4"

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00678.jpg

 

OH YEA! This Flatty has WIDEBODY suspension on it! Although Im sure you could do all this with the flatty strut housings...

http://www.starquestclub.com/forum/index.php?showtopic=76965

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SFBMX88 Newbie

SFBMX88

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I think I couldve cut the Starion housings down a bit more, but this still works and I have a bit more margin to play with. I know some others have cut these down shorter, but everyones different. I was aiming for 22.5"-23" stack height of the front suspension, unloaded, measured from the top of the camber plate to where the spindle meets the steering arm, and I got roughly 23". Ive got maybe 3/4" more adjustment left to raise the car back up if I wanted, but I doubt Ill use it.

 

I now have a few more strut replacement options available to me(KYB, Tokico, Koni, etc,) but most importantly, no more blown inserts!! :D

 

 

why not just cut and thread the stock housing?

 

Because the gland nuts that are included with the AGX inserts have a diameter that is much smaller than that of the Starions.

 

Starion nut bottom, AGX nut on top:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00685.jpg3

 

 

UPDATE 8-3-09

 

Modified front strut tube length is roughly 13 inches from the very top of the housing to where the tube meets the spindle....

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC01428.jpg

 

 

I think it would still be safe to go 1/2 inch to 3/4 inch shorter if you wanted.

 

 

Heres the stock length from the very top of the tube, to where it meets the spindle:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC01490.jpg

 

Edited by SFBMX88
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SFBMX88 Newbie

SFBMX88

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Lessons learned...

 

Measure twice, cut once!

 

Tried welding the Celica tubes on without the nice machined portion and it came out too crooked for my taste, so I had to go back and rethink it all. I also had to get another pair of Celica tubes. That time, I just went back with a pipe cutter and took some right off the top of the strut...

 

NO!!!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09741.jpg

 

BLAH!!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09759.jpg

 

FAIL!!

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC09758.jpg

 

GTFO!! I had to hammer it because I was so disgusted.

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00684.jpg

Edited by SFBMX88
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SFBMX88 Newbie

SFBMX88

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Rears are still in the works.....

 

Based off of blown SHP housings:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/heightREAR.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/insideREAR.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00323.jpg

 

Used some scrap from the front housings to patch over the holes I had to cut out:

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00325.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00326.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00327.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00329.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00330.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00332.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00331.jpg

 

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SFBMX88 Newbie

SFBMX88

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will the longer springs bind at full up travel? i am guessing not since the perch is lower

 

 

Not at all! Infact, there is about a half inch of slack when the suspension is unloaded.

 

 

Great thread! Good pics with measurments. Seems your project is comming a long great.

 

Thanks!

 

Big thanks to Derek(D_Venable) for his thread/advice on the MR2 short stroke conversion. That was a huge help!

Edited by SFBMX88
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Komeuppance Newbie

Komeuppance

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Good work!! How's it ride now??

 

How much did those inserts cost you??

 

BTW, the MR2 tokico illuminas also include new gland nuts that thread into stock starion housings. Good times.

 

-Robert

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SFBMX88 Newbie

SFBMX88

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Good work!! How's it ride now??

 

How much did those inserts cost you??

 

BTW, the MR2 tokico illuminas also include new gland nuts that thread into stock starion housings. Good times.

 

-Robert

 

 

Thanks, inserts are about $95 each at Summit.

 

Are you sure the MR2 Illumina gland nuts fit Starion struts? Im pretty sure they're smaller in diameter.

 

Not quite ready to judge the ride until the rears are installed, but if the AGX inserts are set to 4, you can feel every little bump in the road.

Edited by SFBMX88
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Komeuppance Newbie

Komeuppance

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Yes, 100% sure. I have everything apart, just haven't found the time to cut and weld. I've had everything since... November, or December...

 

UCW458 sent me some front struts from an 87 I believe, tokico gland nuts are the same thread pitch and thread in nicely.

 

-Robert

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SFBMX88 Newbie

SFBMX88

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Yes, 100% sure. I have everything apart, just haven't found the time to cut and weld. I've had everything since... November, or December...

 

UCW458 sent me some front struts from an 87 I believe, tokico gland nuts are the same thread pitch and thread in nicely.

 

-Robert

 

You bought the Illuminas new? The KYB part number I used had a much smaller diameter gland nut than the Starion.

 

I believe Derek has Illuminas too and said that the diameter is different.

 

Here's a pic showing the gland nuts...

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6082.jpg

 

As you can see, the front non-shp gland nut is recessed to capture the insert, with a shim ring for a tighter fit against the KYB replacement, and the rear SHP is "solid".

 

ALSO, both the non-shp, and shp gland nuts have the same thread, and can thread into either of the housings.

 

Edited by SFBMX88
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Komeuppance Newbie

Komeuppance

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Haha, ok, I was misinformed. The nuts I got are KYB gland nuts are for the Starion. MR2 is infact smaller.

 

So my solution without me knowing is, order KYB gland nuts for Starion and they will work with inserts, Tokico or KYB.

 

-Robert

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D_Venable Newbie

D_Venable

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Very nice.

 

I'm planning on doing the same thing with left over material to patch the rear SHP adjustment hole, just haven't gotten to it yet. got a local guy who said he'd tig it all up for me, not sure what he's gonna want though, hehe.

 

I need to get another set of front camber plates, to figure out what I can do with these airbags, hehe

 

Very good idea on the Toyota strut tops, I like the way you went about it too, very nice work :thumbsup:

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SFBMX88 Newbie

SFBMX88

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Thanks Derek!

 

Got abit of an update here. Originally set up, the upper spring hat would rotate on the gold aluminum block for the camber plate when turning. I had been using some grease to offset the wear, but figured the grease would attract too much dirt. After about a week of use, all the grease was dirty and there was already some wear on the aluminum pieces sooo......

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00856.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00857.jpg

 

I ordered some needle bearings and matching washers from http://www.mcmaster.com/#5909k35/=2ng01w

With a 7/8" inner diameter, I figured it should be okay on the 22mm strut shaft since its not really a point of precision.

 

The total thickness of the new assembly was close to 9mm, so I had to readjust the springs to compensate for the increased stack height..

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00858.jpg

 

NO MORE METAL TO METAL WEAR!

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00865.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00869.jpg

Edited by SFBMX88
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SFBMX88 Newbie

SFBMX88

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Looks good! when you get it all done, you have to slam it all the way and take some pics...

 

 

Ill try! I only have about a half inch to an inch more I can lower it before the spanner ring will touch the tire....

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AndyW Newbie

AndyW

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I'm loving the ingeneuity you guys are taking. I'm thinking this winter will be cage installation time and suspension revamping. Thats great you were able to source new springs too. And all this to a flatty too, excelent.
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SFBMX88 Newbie

SFBMX88

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Have some more measurements for the front suspension in case anyone is interested. Ill try to get the final length of just the front strut tube the next time I have the car up...

 

Tokico blues with the proper spacers(for stock length Starion housings) and AGX inserts:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00802.jpg

 

AGX body length and shaft/flange length:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00803.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00806.jpg

 

Tokico body length(w/spacer installed) and shaft/flange length:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00804.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00808.jpg

 

Tokico spacer:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00809.jpg

 

Gland nuts from left to right, Tokico, SHP, AGX:

 

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00811.jpg

http://i5.photobucket.com/albums/y176/sfbmx88vol2/starion-suspension/DSC00812.jpg

Edited by SFBMX88
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