Hi,
So I was not happy with the lowering springs, so decided to do myself a coilovers for the front end, I taught I will share it with You, maybe it will be interesting for some...
I bought a coilover kit: sleeves with threads, adjustment rings, and top cap - 60pounds on Ebay. I did a research and decided to get a 7 inch, 300LB springs - 40pounds on ebay. So in total it was about 100pounds.
Unfortunately almost all components had to be modified, and a lot of things had to be custom made by myself, because there are no bolt on kit for Cougar.
Struts:
Firstly I had to cut out original spring perches from the struts. You have to cut just above the weld line. You have to cut as straight as possible. I did this with a simple angle grinder.
Secondly You have to own a machine tool, because You will never cut that perch perfectly, so it is nice idea to machine a perfectly straight base for that sleeve to sit (or You can just grind everything down and just weld the sleeve to the strut). Also all sleeves on the ebay are 50 or 52 mm ID. You have to buy a 52mm sleeve. Strut OD is also 52mm+paint. So You have to grind all the paint down in order to put the sleeve on (also lube it good, this will also protect from rust, I used heavy duty gear lube thing, it is thick like butter and doesnt run).
Sleeves:
Sleeves are 152mm long. I had to shorten them so they would perfectly fit Monroe struts, and the top plastic cap could be put on and whole assembly would look like factory made.
I shortened them to 105mm.
Locking rings:
Locking rings were the only component that required NO modifications at all. I just made a hard rubber gaskets (top and bottom), so the spring would sit nicely.
Top spring cap:
All top spring caps come with 10mm pilot holes. I machined them to be 22mm, so it would be able to slide them onto the pistons. You have to machine them perfectly - You want that cap to be not too tight and not too loose, there should be no play, but it has to slide down on its weight.
Also the top side of the cap was not flat, I machined it to be perfectly flat. Explained next.
Custom made metal “huge washer-cap”:
I decided to use the original bearings, so I had to make those huge washers to make spring caps (that are now flat) sit on the original bearings. Because all top caps have too small OD. Hole is also 22mm. OD has to be made according to the OD of the original bearing. Also it is a good idea to place a gasket between the top cap ant this washer, so there is no metal on metal in the whole assembly.
Gaskets:
I made all the gaskets myself also. Used hardest rubber I found.
Springs:
I decided to try a 7inch/300lbs springs. If they will be to hard, and the ride too bouncy, Ill take 200, or 250lbs.
Bump stops:
Will cut them in half as the car will be lower that stock.
They are not tested Yet, I plan to put them in during the next week, as far as I think it should work OK, so I cant wait to try
PICTURES:
https://www.dropbox.com/sc/ow39yyl79yplh3j/AAA8L5RrgYsa_yvAjF3MOt_Wa
Thanks,
So I was not happy with the lowering springs, so decided to do myself a coilovers for the front end, I taught I will share it with You, maybe it will be interesting for some...
I bought a coilover kit: sleeves with threads, adjustment rings, and top cap - 60pounds on Ebay. I did a research and decided to get a 7 inch, 300LB springs - 40pounds on ebay. So in total it was about 100pounds.
Unfortunately almost all components had to be modified, and a lot of things had to be custom made by myself, because there are no bolt on kit for Cougar.
Struts:
Firstly I had to cut out original spring perches from the struts. You have to cut just above the weld line. You have to cut as straight as possible. I did this with a simple angle grinder.
Secondly You have to own a machine tool, because You will never cut that perch perfectly, so it is nice idea to machine a perfectly straight base for that sleeve to sit (or You can just grind everything down and just weld the sleeve to the strut). Also all sleeves on the ebay are 50 or 52 mm ID. You have to buy a 52mm sleeve. Strut OD is also 52mm+paint. So You have to grind all the paint down in order to put the sleeve on (also lube it good, this will also protect from rust, I used heavy duty gear lube thing, it is thick like butter and doesnt run).
Sleeves:
Sleeves are 152mm long. I had to shorten them so they would perfectly fit Monroe struts, and the top plastic cap could be put on and whole assembly would look like factory made.
I shortened them to 105mm.
Locking rings:
Locking rings were the only component that required NO modifications at all. I just made a hard rubber gaskets (top and bottom), so the spring would sit nicely.
Top spring cap:
All top spring caps come with 10mm pilot holes. I machined them to be 22mm, so it would be able to slide them onto the pistons. You have to machine them perfectly - You want that cap to be not too tight and not too loose, there should be no play, but it has to slide down on its weight.
Also the top side of the cap was not flat, I machined it to be perfectly flat. Explained next.
Custom made metal “huge washer-cap”:
I decided to use the original bearings, so I had to make those huge washers to make spring caps (that are now flat) sit on the original bearings. Because all top caps have too small OD. Hole is also 22mm. OD has to be made according to the OD of the original bearing. Also it is a good idea to place a gasket between the top cap ant this washer, so there is no metal on metal in the whole assembly.
Gaskets:
I made all the gaskets myself also. Used hardest rubber I found.
Springs:
I decided to try a 7inch/300lbs springs. If they will be to hard, and the ride too bouncy, Ill take 200, or 250lbs.
Bump stops:
Will cut them in half as the car will be lower that stock.
They are not tested Yet, I plan to put them in during the next week, as far as I think it should work OK, so I cant wait to try
PICTURES:
https://www.dropbox.com/sc/ow39yyl79yplh3j/AAA8L5RrgYsa_yvAjF3MOt_Wa
Thanks,
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