Shock Absorbers

[barker_001]

Spent a frustrating day yesterday trying to fit the pair of Avo front shocks I bought at the Lotus Show. DPR's instructions on the "new" forum are excellent, but the trouble I'm having is removing the old ones!

The top nut and locknut refuse to budge; any attempt to turn them just turns the whole top of the old shock. I started to think about hacksawing through the shaft just under the nuts, but didn't want to commit to this (and thus taking the car off the road) until I knew I would be able to remove the bottom bolts. This was where the fun started...

I managed to remove the nylock nuts on both sides, however no amount of release fluid and banging with a hammer will move the bolts. I think they are rusted into the lower bushes of the shocks, thus preventing them from sliding out. The bolts and spacers appear to be available from SJs (waiting for confirmation), so I was thinking of cutting through the bolt and spacer just to either side of the shock bottom bush.

Does anyone have any less destructive suggestions I can try first to remove the bolts?

[AndyC]

Similar issue with some of my old ones, I used a power saw (reciprocating, big thing like Sawzall or whatever the brand is), cut through the nut in the direction of the shaft, so you tan then either spin it off (it slackens on the threads enough) or just cut twice and it is gone.

[robertverhey]

Yep, 'tis only a h/t bolt after all.


You might be able to "assemble" your hacksaw on either side of the bush, and then it can be quickly dispensed with

Robert

[dpr59]

Bryan,

I seem to remeber one side being shall we say, problematic.

I crushed the upper sleeve down onto the strut with a pair of mole grips.
This gave enough purchace to shift the nut.
You can get the grips through the spring when it's extended far enough.
This is of course a one way step and the car is off the road until the job is complete.
However, this is the same as with a saw and trying to cut them off, but might be a bit quicker. If it works.

[barker_001]

Thanks for your comments gents - nice to hear from dpr59 too!

Good news, Steve at SJs has confirmed that the nuts, bolts, and spacers are available - on order today.

So it's out with the saw for the bottom bolts, and mole grips for the top nuts!

[pompey ice]

Hi there I'm busy at the moment trying to sort the brakes ,after much cursing and sweating found two tools that has eased the pain 1,impact driver and 2 nut splitter bought for less than £10 well worth it ,best of luck

Cheers Ian

[MrCoolA]

nut splitter bought for less than £10 well worth it ,best of luck

Cheers Ian

Nut splitters are ACE

[barker_001]

I've never seen them before, what a great idea!

Sadly though I wouldn't be able to use them in this case - the nuts actually came off fairly easily, it's where the bottom bush of the shock has rusted to the bolt that's the problem. I'm just trying to source one of those nice reciprocating saws with a metal cutting blade...

[robertverhey]

Standard hacksaw will do it, if you assembe it around area in question

[Gavin Hamson]

Bryan,

Are the AVO shocks the direct replacement polybush type? If so, you will find the lower eye/bush is wider than the original shock and the spacers will need machining.

Gavin.

[MrCoolA]

if you get them from Mike's that is included in the kit............

[barker_001]

They are the polybush type and were from Christopher Neils. Due to work commitments I haven't had a chance to do any more on the car, but I had a suspicion the bottom bush looked a bit wider than the Spax ones that were on there. The new Lotus spacers I bought are each 10mm thick, and the width of the shock bush is 39mm - how much did you have to take off, Gavin? Incidentally, what do you think of the AVOs, and how many "clicks" did you end up with?

[Gavin Hamson]

if you get them from Mike's that is included in the kit............

I bought from Lotusbits the AVO shocks to be used with the standard springs, not the coil-over kit they do. I didn't get any fixings or spacers.

I am sorry Bryan, but I don't remember what needs to be machined off. I used a vernier caliper to measure up, the fit of all should be quite snug.
I put a large outside diameter washer either side of the lower eye/bush, and then the spacers either side. Use Copaslip on the bolt.

I am pleased with them, ride and handling is still very good. I'll check the clicks - Mike at lotusbits advised me on the settings and they seem OK.

[barker_001]

I've just taken some measurements with my Vernier caliper.

Width of the gap in the lower suspension arm: 53.4mm

Width of AVO shock plus two spacers: 58mm

Therefore 2.3mm to be removed from each spacer.

Also, the AVO shock is considerably fatter than the original - the metal body is 51mm diameter, however I can only squeeze the rubber sleeve down to 56mm so it looks like it won't go up through the gap in the suspension arm. How did you get around this? It seems the AVOs are not a "direct replacement"!

[Lotus-e-Clan]

For those about to change dampers and wanting a more "direct replacement", GAZ rear dampers fit straight out of the box. 17 clicks on the rear and jobs a good-un.