DiscoveryRangie
Mine isThose Disco's are fast!
Well not that one. But some are
Yea it's nice to have people over talking through what we did with parts and stuff, keeps things interesting, unfortunately a lot of the sport has gone away from homebrew cars to bought in things and bolt on kits so it's a bit different still.
Story of my life helping others out all the timeThat's our problem atm, got a friends car in the back for the last 2 months so the poor buggy got it's upgrades delayed![]()
I wanted to put fox air shocks on my old off-roader but no one knew anything about them at the time over 15 years ago now. I’d still love them, do they eliminate body roll?As for the revalving, well that was fun - one of the dampers it turns out didn't have the backup washer the correct way around/torqued enough and caused a little wear - nothing on the important bits but you can see the debris on the ally bearing spacer here:
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And it also looks like the bleed shims (the big shims on the left with the cutouts) were oriented wrongly - where you'd assume the tabs line up with the little raised bits on the piston, they were 45* rotated on that damper, which then leads to some odd effects as the initial compression pressure acts on the shim stacks behind those and the bleed shims themselves only start to lift in the high speed area.
Unfortunately, I've never been in these dampers before and Fox never used to run bleed shims (they ran holes in the piston for it instead - finally they've moved to the same system you see on most high end stuff with Ohlins/Penske/Reiger to make it easy to change bleed amounts) - so after spotting that I just assumed it was deliberate to soften initial response, and kept things that way around when I rebuilt it.
It was only when I opened the last damper that had the shims the way around I originally expected - and no wear, I realised I should have assembled those bleed shims as I originally intended!
Anyway just for this race I've put the bleed shims back together the way the initial one was setup, and then I'll turn them around for the next race after re-running some fluid sims - I just simply don't have time to correct it right now, and I wasn't expecting basically brand new dampers to be mis-assembled. Should have trusted my instincts there.
I have made quite a change though, there's much less low speed bleed now so that I don't have to rely on running the adjusters on max (that causes issues with sensitivity and the pressure balance inside the dampers).
The flutter stack is massively reduced on the compression side, which is referring to the small shims backing up the large washers on the bottom in the middle there - basically that makes a 2 stage stack so the low/mid speed damping is reduced a lot and the high speed is very stiff. That's fine for the UTV these were coming off where they need to get it suitable for everyone from comfy road use to people hammering them over dunes, but it's also softening the damping right where a race car like this needs it - jump landings, bottoming out from elevation changes, washboard stuff where it's dug out in the mud, etc.
It's almost the same for the rebound side (the top shims) - they've used a flutter stack to give the rebound adjuster more range and with a soft initial stack and then a stiffer high speed stack they can cope with a wide range of spring rates owners are likely to throw at a UTV, basically running a progressive damping curve but with the option to add a lot of low speed rebound control.
That unfortunately for us with quite a lot of spring preload and weight at the rear means that the damping is reduced right where it's controlling the rear kicking up over rolling jumps, as you can see on some of the jump pictures it lands nose heavy a lot of times if it's a steep take off.
The only way to really tame that was to wind the rebound adjuster to almost full hard (it adjusts the low speed mainly but also the mid speed damping somewhat) - but because that also winds up the low speed damping which is mainly body control and handling related, that would make the car very nervous and skitterish on the brakes or the way into a corner so I couldn't go too far.
Given we also don't need that range of adjustment I've pulled that stack completely and now it runs a more conventional tapered stack that gives slightly digressive rebound damping, that means we have a lot more midrange damping, and I can just use the adjuster for what it was designed for - tailoring the handling responses of the car rather than trying to patch up problems in the main valve stack.
I've left the high-speed damping somewhat similar at the moment just for reference but I suspect I'll end up reducing that somewhat anyway, we have quite a lot of unsprung weight, and our tyres are both quite a lot larger and run lower pressures than an UTV - so I think a softer setup there will benefit us more in terms of getting the tyre back in contact with the road sooner vs the sudden increase in contact patch pressure that might cause.
One for another time
Anyway, after all that rambling they're back together and re-gassed:
![]()
I also swapped the oil to some low-friction oil - the stock Fox red oil isn't too bad but it has some really bad issues with stiction I've noticed over the years - especially in dampers this size, not so much of an issue in smaller stuff, whereas the stuff I'm using now has some really fancy additive package to reduce friction and wear at the expense of needing changing a little more often.
...while I'm rambling about dampers I wasn't impressed by the pistons either - they're very low flow so they choke the valving on impacts and they have a lot of sharp edge entries into the ports too. I'll be swapping those out for either some higher flow alternatives when I can get hold of some (Fox sell them for racers in the US), or making a pair.
I was helping out with my nephew autograssing last yr - someone went in a bit clumsy and sideswiped him, came in with a broken coilover. We had a spare but I couldn’t help having a look inside. The stem itself was hollow, for the adjuster, and threaded. Trouble was there was so little steel because of the thread and drilling, the sideswipe snapped it. I’m not saying this was a fox damper (cos I’m old and have a crap memory), but I wasn’t impressed...As for the revalving, well that was fun - one of the dampers it turns out didn't have the backup washer the correct way around/torqued enough and caused a little wear - nothing on the important bits but you can see the debris on the ally bearing spacer here:
![]()
And it also looks like the bleed shims (the big shims on the left with the cutouts) were oriented wrongly - where you'd assume the tabs line up with the little raised bits on the piston, they were 45* rotated on that damper, which then leads to some odd effects as the initial compression pressure acts on the shim stacks behind those and the bleed shims themselves only start to lift in the high speed area.
Unfortunately, I've never been in these dampers before and Fox never used to run bleed shims (they ran holes in the piston for it instead - finally they've moved to the same system you see on most high end stuff with Ohlins/Penske/Reiger to make it easy to change bleed amounts) - so after spotting that I just assumed it was deliberate to soften initial response, and kept things that way around when I rebuilt it.
It was only when I opened the last damper that had the shims the way around I originally expected - and no wear, I realised I should have assembled those bleed shims as I originally intended!
Anyway just for this race I've put the bleed shims back together the way the initial one was setup, and then I'll turn them around for the next race after re-running some fluid sims - I just simply don't have time to correct it right now, and I wasn't expecting basically brand new dampers to be mis-assembled. Should have trusted my instincts there.
I have made quite a change though, there's much less low speed bleed now so that I don't have to rely on running the adjusters on max (that causes issues with sensitivity and the pressure balance inside the dampers).
The flutter stack is massively reduced on the compression side, which is referring to the small shims backing up the large washers on the bottom in the middle there - basically that makes a 2 stage stack so the low/mid speed damping is reduced a lot and the high speed is very stiff. That's fine for the UTV these were coming off where they need to get it suitable for everyone from comfy road use to people hammering them over dunes, but it's also softening the damping right where a race car like this needs it - jump landings, bottoming out from elevation changes, washboard stuff where it's dug out in the mud, etc.
It's almost the same for the rebound side (the top shims) - they've used a flutter stack to give the rebound adjuster more range and with a soft initial stack and then a stiffer high speed stack they can cope with a wide range of spring rates owners are likely to throw at a UTV, basically running a progressive damping curve but with the option to add a lot of low speed rebound control.
That unfortunately for us with quite a lot of spring preload and weight at the rear means that the damping is reduced right where it's controlling the rear kicking up over rolling jumps, as you can see on some of the jump pictures it lands nose heavy a lot of times if it's a steep take off.
The only way to really tame that was to wind the rebound adjuster to almost full hard (it adjusts the low speed mainly but also the mid speed damping somewhat) - but because that also winds up the low speed damping which is mainly body control and handling related, that would make the car very nervous and skitterish on the brakes or the way into a corner so I couldn't go too far.
Given we also don't need that range of adjustment I've pulled that stack completely and now it runs a more conventional tapered stack that gives slightly digressive rebound damping, that means we have a lot more midrange damping, and I can just use the adjuster for what it was designed for - tailoring the handling responses of the car rather than trying to patch up problems in the main valve stack.
I've left the high-speed damping somewhat similar at the moment just for reference but I suspect I'll end up reducing that somewhat anyway, we have quite a lot of unsprung weight, and our tyres are both quite a lot larger and run lower pressures than an UTV - so I think a softer setup there will benefit us more in terms of getting the tyre back in contact with the road sooner vs the sudden increase in contact patch pressure that might cause.
One for another time
Anyway, after all that rambling they're back together and re-gassed:
![]()
I also swapped the oil to some low-friction oil - the stock Fox red oil isn't too bad but it has some really bad issues with stiction I've noticed over the years - especially in dampers this size, not so much of an issue in smaller stuff, whereas the stuff I'm using now has some really fancy additive package to reduce friction and wear at the expense of needing changing a little more often.
...while I'm rambling about dampers I wasn't impressed by the pistons either - they're very low flow so they choke the valving on impacts and they have a lot of sharp edge entries into the ports too. I'll be swapping those out for either some higher flow alternatives when I can get hold of some (Fox sell them for racers in the US), or making a pair.
I wanted to put fox air shocks on my old off-roader but no one knew anything about them at the time over 15 years ago now. I’d still love them, do they eliminate body roll?