Hydraulic Height Adjustable Suspension - Almost Finished

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

I just submitted my application for my final year project (like a thesis)

Topic: Demand Based Suspension Lift

The sort that was available on gen2 pajeroâ€™s in japan.

So all that are interested put you hands up: if I am making 1 I might as well make a few more.

Issues:

Engineering Certificates (hoping I can get it certified as a bolt on accessory or something (donâ€™t know much about this)

Time (this subject is 2 semesters long)

Information: I donâ€™t have access to one of these systems, so Iâ€™m going to be asking a lot of questions in the near future.

if anybody can provide me with info of any sort, that would be greatly appreciated,

I have seen theses posts

http://www.4x4wire.com/forums/showflat.php?Cat=&Number=1010964&page=&view=&sb=5&o=&fpart=1&vc=1
http://www.outerlimits4x4.com/phpBB2/viewtopic.php?t=41356&highlight=adjustable
http://www.outerlimits4x4.com/phpBB2/viewtopic.php?t=53867&highlight=adjustable
http://www.outerlimits4x4.com/phpBB2/viewtopic.php?t=58503&highlight=adjustable
http://www.outerlimits4x4.com/phpBB2/viewtopic.php?t=98472&highlight=adjustable

Thanks,

Dave

Joined: 21 Mar 2007 Location: brisbane

hey dave

my truck has the system and works fine, but i am interested as i don't expect it to last forever.

nice front bar, did you make it?

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

you will probably be hearing a lot from me then jop Wink

Joined: 21 Mar 2007 Location: brisbane

no dramas

Joined: 21 Mar 2007 Location: brisbane

The difference between normal and hydraulicly lifted ride height

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

Hi all,

Just an update and a few questions

I have started the hydraulic cylinder calculations (stroke/force) and have got a few questions

What is considered the maximum height you can wind up the torsion bars.

Looking at the top bump-stop, it appears it won't take much â€œwindingâ€ before it is constantly running on it. I could cut the bump-stop down a bit to allow more droop, but will this adversely affect the handling when the vehicle is at normal ride height (Im guessing not).

I guess what i am really asking, is what is the lift height on the front of the car, and how have they allowed for the bump-stop issues in these import cars.

If possible, could I get some pics of the hydraulic cylinders in both the front and rear and their bumpstop setup. All I have is the Wincaps pics posted a here a while ago.

So far I have allowed for 50mm lift front and rear

Any help would be greatly appreciated

P.S. I have spoken to a cert engineer and he canâ€™t see anything illegal with what I am doing (as long as it is not too high).

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

Its been a long time since an update, so I thought I would do one.

As of today, the hydraulic system is installed. I have spent the last few weekends pulling the car apart and chucking the hydraulic cylinders in.

Over the summer uni break, I spent most of my time working with the uni’s manufacturing department getting the cylinders machined up.

Rear Assembly (Push Cylinder)

Front Cylinder (Pull Cylinder)

So to make everything easier, I installed a body lift . Made access to these bolts + port possible. Also did the whole Gear stick thing, But chose to cut with a grinder + Weld + grind smooth again.

Did a fair bit of grinding to get rid of the old coil mount.

The hydraulics is powered from a 12V Power pack off a tailgate lift. The punp was donated from All Trans Truck and Spares. This was a great help because these are expensive. It pretty much made the whole project possible.

All in or, it works, the back goes up first cause there is less weight then the front. I’m thinking about installing some flow control to get it to go up level, but could be a little difficult.

Future work is looking at being able to control each corner of the car individually. This was priced at over $400 per wheel, so it might have to wait till I get a full time job. This could lead into active suspension if the reaction time is good enough. (Be able to stabilize myself around corners + ride leveling with loads etc.

I would like to thank Kevin from Excel Hydraulics. He helped me out immensely on both the technical side of the cylinder and also offered a great price on the hydraulic hoses and fittings.

I would also like to thank Trevor form Adcot engineering Services. He volunteered to sign off on the vehicle as an engineering signatory free of charge. (still looking into this). I highly recommend his services, he was more than happy to answer my questions, and help me out.

A years work for 50mm lift. Probably not worth it, but I learnt a sh*t load in the process.

Will post up a video when i get a chance. Its dark now so i might try tomorrow + a PDf of Drawings maybe.

Joined: 02 Jan 2008 Location: Mackay, Sunshine State

Yeah a year for 50mm lift does seems a bit like it wasn't worth it (when your looking from the outside in) but I wouldn't doubt the fact you learnt a shi'tload.

With that amount of time could've looked at producing a SAS kit for Pajeros and Tritons. Or was there a paticular type of lifting system you had to develop in your course?

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

I was pretty free to choose any project i wanted to. Usually they are theory based. Im one of the few students that actually made something.

I dont know why i made it, i just aways wanted one. i originally thought there would be more people interested in it, but for the price vs lift + possible reliability issues, i can understand why people dont want it.

Joined: 22 Oct 2002 Location: brisbane

Maybe you should have asked a few more q's! Laughing

but it does look like you did some nice work!!

i can retofit SAW shocks for under $350 each giving 10"-18" of lift on demand!! this is a vid of our initial test, the higher you go the stiffer and more stable they get.

Joined: 01 Jul 2007 Location: On the Trail

1MadEngineer wrote:

Maybe you should have asked a few more q's! Laughing

but it does look like you did some nice work!!

i can retofit SAW shocks for under $350 each giving 10"-18" of lift on demand!! this is a vid of our initial test, the higher you go the stiffer and more stable they get.

Not to hijack but can you retro coilovers?

Jason

Joined: 02 Jan 2008 Location: Mackay, Sunshine State

1MadEngineer wrote:

Maybe you should have asked a few more q's! Laughing

but it does look like you did some nice work!!

i can retofit SAW shocks for under $350 each giving 10"-18" of lift on demand!! this is a vid of our initial test, the higher you go the stiffer and more stable they get.

Nice, but kinda pointless on IFS don't ya think. Or have you found a way around that? (apart from s.a.s) Interested if you have.

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

[quote="clm434"]

1MadEngineer wrote:

Maybe you should have asked a few more q's! Laughing

but it does look like you did some nice work!!

i can retofit SAW shocks for under $350 each giving 10"-18" of lift on demand!! this is a vid of our initial test, the higher you go the stiffer and more stable they get.

Nice, but kinda pointless on IFS don't ya think. Or have you found a way around that? (apart from s.a.s) Interested if you have.

Yeah i was never interested in building a crawler or anything. The whole project was based on the lifting system already availabe on some pajeros. It was always going to be limited by the IFS.

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

Finally did some videos,

Whole Car (4.7 meg)
http://www.whiteovergreen.com/uni/OL/Hyd/Whole%20Vehicle.wmv

Front + under car view (7.8 meg)
http://www.whiteovergreen.com/uni/OL/Hyd/Front.wmv

Rear + under car view (7.4 meg)
http://www.whiteovergreen.com/uni/OL/Hyd/Rear.wmv

Ive also got a massive report if you guys need more info. (190 pages with 50 manufacturing drawings)

Dave
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Joined: 21 May 2007 Location: Norway

Wouldn`t mind a copy of your report. How much would you charge to make me a system?

Joined: 16 Aug 2004 Location: Down Under - Sid a nie

Hi cbsickboy,

Sorry for my late reply

Looking back at the price for everything, it would be way too expensive to manufacture again.

I spent ~ $1500 and that was without machining labour. The machine shop also supplied some material and a hydraulic power pack was donated.

Machining and the power pack would be expensive.

All I can do is give you the plans, and offer recommendations as to how the system can be improved. If you go ahead with it, I can answer any questions.

The report has been PM’ed

Joined: 21 May 2007 Location: Norway

Nice going m8. Cheers for that.