BC

I have been working on getting some pieces made so that I can easily put hypercoil-type springs onto a couple sets of bilsteins that I have around the garage. Technically, all you really need, at least for the bilsteins, are a metal hat that goes between the oem spring hats and the skinnier hypercoil springs.

So I made this in emachineshop:





The design is relatively simple, but when I want to make just 4 of them, they become 50 dollars each. If I make more than 10, they become in the 32 dollar range. Money saved.

I am still working on the rears - they have a sort of radius that is difficult to do in the very archaic emachineshop software.

If I could get enough people to want all four corners, we may be able to get the caps done for around 30 bucks each, making all four corners 120 bucks. Since hypercoil springs are relatively cheap, you could have yourself a very cheap coilover package. Shocks are your deal, of course.

Remember that the holes are different for these spring caps/hats between bilstein and koni. Koni shock shafts are more like .552 IIRC, and Bilstein shafts are .570

I already need four fronts and four rears. I was thinking of trying to make the shape universal for front and rear, but that would not work, I would guess, as the angles by which you want these mating with the oem stuff is quite different - the rear has a rounder mating surface than the fronts.

BC

You can sort of see the rear hat here - how it is much more flat and also has a radius going to the angle:

BC

I just finished the rear.

BC

If anybody has any advice please post. Maybe making it lighter (it doesn't need to be strong), or changing anything.

Tom. M

Why re-invent the wheel? Just pick up one that is already out there. Don't remember the exact total, but there's less than $200 in my setup including hypercoils/hats (for all four corners)...

Tim Murphy

Hey Brendan, your wheels are on backwards

Tom. M

Here's a front one..

BC

Oh yeah. They went on to another life. Those were nice, light wheels though.

BC

Thanks Tom. I did see these - looks great. I am looking for a slightly more completed process - with top and bottom needle-bearing supports, as well as a bit of a shoulder where the spring will be located. Especially for a street car. The springs moving and shifting is very disconcerting. Since the tops are mostly rubber, the shock could technically move around a conical axis as the arms go through non-up-and-down motions - and this can move the spring away from its current position you posted.

RyanPerrella

Im potentially interested

interesting this comes up as i just was talking about something similar in another thread

I would be interested in the $30 per unit price

I need to read up more on it to see if i like the direction your going but i think what your trying to do is what i would be trying to do as well.

im interested, I love the bilsteins and would like a lighter spring as well

BC

I think I can get there with you, me, and someone who PMd me. Thats 8 of each. I'll update.

BC

I am thinking of actually getting these made. Is there any interest at all?

Bill Ball

PM sent.

BC

PM replied. I will post costs here.

FBIII

If the price is reasonable I'm interested.