BigEd0601's Photobucket Coil-overs album media

What I start with-1/8" alum. tube for the body & reservoir, 5/32" alum. tube for the coil spring retainers, Evergreen 3/32" plastic tube for the end mounts.The .080 rod was too small,the .100-too big, small paper clips.

BigEd0601 — Tue, 25 Sep 2007 21:42:47 MDT

BigEd0601 posted a photo

What I start with-1/8" alum. tube for the body & reservoir, 5/32" alum. tube for the coil spring retainers, Evergreen 3/32" plastic tube for the end mounts.The .080 rod was too small,the .100-too big, small paper clips. - 100_0527.jpg

I use the longest side of the paper clip...

BigEd0601 — Tue, 25 Sep 2007 21:42:06 MDT

BigEd0601 posted a photo

I use the longest side of the paper clip... - 100_0542.jpg

Take your flat file and flatten one side of the plastic tube, but not all the way thru...

BigEd0601 — Tue, 25 Sep 2007 21:41:32 MDT

BigEd0601 posted a photo

Take your flat file and flatten one side of the plastic tube, but not all the way thru... - 100_0547.jpg

Use a pencil if you have to to mark around the tube & flatten the other side...

BigEd0601 — Tue, 25 Sep 2007 21:40:55 MDT

BigEd0601 posted a photo

Use a pencil if you have to to mark around the tube & flatten the other side... - 100_0550.jpg

Sand the opposite edges (ones you didn't flatten) round to form a half-circle...sorry about the pic focus...

BigEd0601 — Tue, 25 Sep 2007 21:40:29 MDT

BigEd0601 posted a photo

Sand the opposite edges (ones you didn't flatten) round to form a half-circle...sorry about the pic focus... - 100_0565-3.jpg

Cut your shock end about 1/16" from bottom of flattened area (second pencil line down). These are approximate...size it to your liking...

BigEd0601 — Tue, 25 Sep 2007 21:40:02 MDT

BigEd0601 posted a photo

Cut your shock end about 1/16" from bottom of flattened area (second pencil line down). These are approximate...size it to your liking... - 100_0577.jpg

Top shock end, shock body >>

BigEd0601 — Tue, 25 Sep 2007 21:36:58 MDT

BigEd0601 posted a photo

Top shock end, shock body >> - 100_0580-5.jpg

with shaft (again, sorry for the bad focus)...

BigEd0601 — Tue, 25 Sep 2007 21:00:36 MDT

BigEd0601 posted a photo

with shaft (again, sorry for the bad focus)... - 100_0582-1.jpg

Cut a small piece of the plastic tube like at the top of shaft. Then cut another piece twice as long...glue the small one to the top of the shaft. Let it sit for a few..

BigEd0601 — Tue, 25 Sep 2007 21:00:02 MDT

BigEd0601 posted a photo

Cut a small piece of the plastic tube like at the top of shaft. Then cut another piece twice as long...glue the small one to the top of the shaft. Let it sit for a few.. - 100_0583.jpg

I call the small one the slider (that's what it does), the large one the "stop" (that's what IT does)...

BigEd0601 — Tue, 25 Sep 2007 20:59:17 MDT

BigEd0601 posted a photo

I call the small one the slider (that's what it does), the large one the "stop" (that's what IT does)... - 100_0587.jpg

Push slider insde body...do not glue. The plastic stop you can glue flush with the bottom of the body if it's not a snug fit.

BigEd0601 — Tue, 25 Sep 2007 20:58:44 MDT

BigEd0601 posted a photo

Push slider insde body...do not glue. The plastic stop you can glue flush with the bottom of the body if it's not a snug fit. - 100_0590.jpg

Same as next pic, just a different angle.

BigEd0601 — Tue, 25 Sep 2007 20:54:31 MDT

BigEd0601 posted a photo

Same as next pic, just a different angle. - 100_0594-1.jpg

Shock with plastic slider & stop installed in the body...

BigEd0601 — Tue, 25 Sep 2007 20:52:19 MDT

BigEd0601 posted a photo

Shock with plastic slider & stop installed in the body... - 100_0595.jpg

Make another shock end only cut it 1/8" from the bottom of the flattened area (similar to the earlier end, only longer)...

BigEd0601 — Tue, 25 Sep 2007 20:47:07 MDT

BigEd0601 posted a photo

Make another shock end only cut it 1/8" from the bottom of the flattened area (similar to the earlier end, only longer)... - 100_0602.jpg

Under the body are the 3 pieces that make up the bottom shock mount. The smaller but longer tube (same as body) is about 1/8" long. The wide collar is about 1/16" (approx. sizes)...

BigEd0601 — Tue, 25 Sep 2007 20:44:24 MDT

BigEd0601 posted a photo

Under the body are the 3 pieces that make up the bottom shock mount. The smaller but longer tube (same as body) is about 1/8" long. The wide collar is about 1/16" (approx. sizes)... - 100_0607.jpg

This is the 3 pieces assembled...

BigEd0601 — Tue, 25 Sep 2007 20:40:26 MDT

BigEd0601 posted a photo

This is the 3 pieces assembled... - 100_0613-1.jpg

Glue the bottom shock end to the shock shaft but not past the small hole you drilled in it earlier (stick a pin in the hole so the shaft stops there.

BigEd0601 — Tue, 25 Sep 2007 20:38:25 MDT

BigEd0601 posted a photo

Glue the bottom shock end to the shock shaft but not past the small hole you drilled in it earlier (stick a pin in the hole so the shaft stops there. - 100_0614-1.jpg

Basic shock assembly minus the top collar...

BigEd0601 — Tue, 25 Sep 2007 20:11:47 MDT

BigEd0601 posted a photo

Basic shock assembly minus the top collar... - 100_0534-1.jpg

Shock has the plastic coil retainer (collar) at the top. You can use aluminum also.

BigEd0601 — Tue, 25 Sep 2007 20:06:53 MDT

BigEd0601 posted a photo

Shock has the plastic coil retainer (collar) at the top. You can use aluminum also. - 100_0623-1.jpg

You'll see the alum. collar is slightly adjustable-about 2 1/2 scale inches...>

BigEd0601 — Tue, 25 Sep 2007 20:06:06 MDT

BigEd0601 posted a photo

You'll see the alum. collar is slightly adjustable-about 2 1/2 scale inches...> - 100_0628.jpg

Set the ride height before gluing collar.

BigEd0601 — Tue, 25 Sep 2007 20:06:05 MDT

BigEd0601 posted a photo

Set the ride height before gluing collar. - 100_0629.jpg