Posts Tagged ‘ Poly Bushes ’

Engine Bed and Bush Replacement

In preparation for replacing the engine bed bushes and front anti roll bar bushes a second engine bed was sourced. I decided to prepare another engine bed with the uprated polyurethane bed bushes and then swap the beds over, rather than to fit the new bushes to the current subframe already fitted to the car. It also meant the replacement subframe could be painted first before being fitted to the car, as the subframes are subject to surface corrosion. Preparing a second subframe will make the whole process easier, rather than having to remove and then paint the current subframe fitted to the car.

The new subframe will be cleaned up, the areas of rust removed, treated with a rust neutraliser, primed with a zinc primer (given several coats) and finally painted with a rust-proof metal paint, again given several coats. Then the uprated subframe bushes can be fitted to the new subframe.

The existing subframe will then be removed from the car, the front anti roll bar (with new uprated anti roll bar bushes), uprated rear engine mount, wishbones and power steering rack will be transferred across to the new subframe which will be fitted onto the car. At the same time a PAS fluid change will be carried out.

So to begin, one engine bed after a quick clean up and degrease to get rid of the worst of the grime, and with the original subframe bushes and wishbones removed:

Engine Subframe

Engine Subframe

Engine Subframe

Engine Subframe

So the next stage was to strip it back and remove the main areas of surface rust, after which the subframe was treated with an anti-rust neutraliser to give a stable sound bonded surface, followed by zinc priming in preparation for the top coat.

The final stage was to paint the subframe with a metal protection paint to give it an OE look.

Finished Subframe

Finished Subframe

Finished Subframe

Finished Subframe

During preparation, priming and painting particular attention was paid to the areas that are most susceptible to corrosion, mainly the areas where the subframe has been welded.

And with the uprated bushes fitted.

Astra Subframe with Uprated Polyurethane Bushes Fitted

Astra Subframe with Uprated Polyurethane Bushes Fitted

Just the the swap over to do.

12/01/2015
The original subframe was removed from the car and the front wishbones, front anti roll bar and power steering rack were swapped over onto the new subframe with the uprated black series Powerflex bushes which was then refitted onto the car.

At the same time the factory anti roll bar bushes were replaced with Powerflex black series uprated anti roll bar bushes and the power steering fluid was replaced with new Pentosin CHF 202 fluid, as it had most likely been in use since day one.

The exposed captive nuts and subframe bolts were treated to some AL1100 anti-seize spray when refitted, as it is not uncommon for the bolts to seize in. This is especially common due to corrosion from winter salt, which fortunately the car does not get exposed to. Additionally the exposed areas of the chassis were treated with Waxoyl underseal.

Underside

Underside

Underside

Underside

Polyurethane Anti Roll Bar Bushes

The car is currently running the original factory anti roll bar bushes (which have now covered 88,000 miles) and these have never been changed so it is about time they were replaced. To replace them I have a pair of Powerflex Black Series track spec (95 Shore) anti roll bar bushes ready to fit.

This will be a job to do when the engine bed/subframe is dropped as I will be fitting a set of uprated engine bed bushes over the winter. Due to the location of the front anti roll bar on the engine subframe, replacing these bushes with the subframe on the car is all but impossible. With the subframe off it makes the job so much easier.

The aim is to get these fitted during December.

1 Piece Replacement Poly Bush (shown in road spec 80 shore purple material – left) and Original 2 Piece Rubber Bush (right):

Poly 1 Piece ARB Bush and Original 2 Piece ARB Bush

Poly 1 Piece ARB Bush and Original 2 Piece ARB Bush

Front ARB Bushes in Black track spec 95 shore material:

Anti Roll Bar Bush - Black Material 95 Shore

Anti Roll Bar Bush – Black Material 95 Shore

Front Suspension Bushes

The car has covered about 85,000 miles, and since it is being used on track an upgrade to the factory rubber bushes is in order. Whiteline Polyurethane Front Wishbone Bushes are being used, and at the same time due to the age and mileage of the original ball joints and drop links they are also having a refresh at the same time whilst everything is apart.

So here are the Whiteline front wishbone front poly bushes, new genuine original equipment (OE) drop links (anti roll bar links) and new genuine OE replacement bottom ball joints:

Poly Bushes, New Drop Links and Bottom Ball Joints

Poly Bushes, New Drop Links and Bottom Ball Joints

Poly Bushes come as a replacement bush in two halves for easier fitting with a heavy duty central metal sleeve. The Whiteline poly bushes below are the front wishbone rear bushes which give a small caster change, to improve positive caster for better turn in.

Whiteline Black Poly Bushes

Whiteline Black Poly Bushes

Whiteline poly bushes have a shore hardness of around 85-90, and so are much stiffer than factory rubber bushes.

New wishbone to engine bed/subframe nuts and bolts:

Wishbone Retaining Bolts

Wishbone Retaining Bolts

Front Wishbone removed from the car, the bushes will be knocked out along with the removal of the ball joints:

Front Wishbone

Front Wishbone

From the factory the original bottom ball joints are riveted onto the wishbone, so to remove them the rivets on the OE ball joints are drilled out using suitable sized drills first (wear protective goggles!):

Removing OE Bottom Ball Joint

Removing OE Bottom Ball Joint

Then supported on a suitable old socket or similar the rivets can be tapped out allowing the ball joint to be removed from the wishbone:

OE Rivets Removed

OE Rivets Removed

Poly bushes have been fitted into the wishbone and the new genuine bottom ball joint has been fitted and secured with the supplied bolts and stover type lock nuts and is a perfect fit:

Bushes and Ball Joint Fitted

Bushes and Ball Joint Fitted

Front Wishbone from another angle showing the caster change bush fitted:

Camber Adjust Rear Poly Bush

Camber Adjust Rear Poly Bush

Eibach camber adjustment bolts to allow some additional negative front camber to be added:

Eibach Camber Bolts

Eibach Camber Bolts

Astra VXR Sprint.....

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