Ironman Foamcell Pro Group Buy

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Getting closer.. Looking forward to the upgrade Mark, the billies are starting to sh!t me.

Thanks for your time and dedication to this project, I bet your significant other is enjoying some peaceful time by her/himself with you working away in the shed. I know mine does when I am.

Maybe you should start another group buy on here for us to get her/him some flowers or a bottle of something to say thanks..

Cheers

Hey Adrian,

Yep definitely getting close to you now, the next batch of stock I get in I'll hopefully get enough gear to get up to 25 on the list very quickly! I need to get the list completed by late September, so I'll be pushing even harder as long as my arms don't fall off!

Actually my wife has helped on every single revalve, she is the chief oil topper upper during bleeding! No problem to crowd fund a carton of bundies for her...might even chuck a few back myself!

Best

Mark

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Getting closer.. Looking forward to the upgrade Mark, the billies are starting to sh!t me.

Thanks for your time and dedication to this project, I bet your significant other is enjoying some peaceful time by her/himself with you working away in the shed. I know mine does when I am.

Maybe you should start another group buy on here for us to get her/him some flowers or a bottle of something to say thanks..

Cheers

The payment is a bottle of rum. He wont accept Pyrat though.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

The payment is a bottle of rum. He wont accept Pyrat though.

Gotta say I'm looking longingly at the empty bottle of RZ on my bench!! Thank you Sir!

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Gotta say I'm looking longingly at the empty bottle of RZ on my bench!! Thank you Sir!

I hate how quickly Ron evaporates once he is opened! Worth the trouble of drinking it raw!!!

[Nova Member Find all posts View Profile Close Nova]

Does anyone know if Tin's rear stone guards will fit these shocks?

Cheers, Nova

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Does anyone know if Tin's rear stone guards will fit these shocks?

Cheers, Nova

Hey,

I think Photoprado has been making some measurements for Tin to do this!

Best

Mark

[photoprado Avid PP Poster! Find all posts View Profile Close photoprado]

Yep. Sent measurement details to Tin. In due course there should be a group buy of Tin's guards for these shocks.

The original Tin's stone guards are too small to fit the Ironmen.

[404pug Avid PP Poster! Find all posts View Profile Close 404pug]

That would be the same issue with the OME ones as well then I assume. They are designed for a smaller shock. I shall have a fiddle with them over the next few days to confirm.

[Mkeech Lurker Find all posts View Profile Close Mkeech]

In between showers during the week and finishing yesterday my suspension upgrade including AMTS air bag to coil convertion is all complete on the 07 Grande and a few short test drives yesterday and this morning and WOW !!!!!! it is awesome !!! very slightly firm in the rear but all my recovery gear and filling the rear drawers will sort that.
The most surprising thing besides speed bumps and a few kerb runs is that although its up at least 2" it feels like its lowered - the handling is fantastic, can't wait t go bush !
What an amazing effort Mark, not only that but having me drive you nuts with questions during the install, and Andrew also fantastic to deal with and always ready to give advise ...... Thanks again Guys
lca bushes all freed up and ready for alignment I've got 790 and 840 after only about 20km's , considering adjusting the front up another 5 -8mm just to give a slightly better aesthetic angle once everything settles (have airbag man spring bags in the rear for the Camper trailer) any thoughts ? do this adjustment - test drive, then alignment ?

[krypto Avid PP Poster! Find all posts View Profile Close krypto]

Been down south and driving back to back with stock suspension Prado, Whiteys setup is actually more compliant over small hits such as potholes and corrugations.

[drwormy Junior Member Find all posts View Profile Close drwormy]

The front will likely settle at a rate 1.8 times the rear, due to the motion ratio, and in my experince, after a week, it comes down ~ 20 mm from first bounce, and ~ 10 mm from a little drive. Id go with your suggestion.

In between showers during the week and finishing yesterday my suspension upgrade including AMTS air bag to coil convertion is all complete on the 07 Grande and a few short test drives yesterday and this morning and WOW !!!!!! it is awesome !!! very slightly firm in the rear but all my recovery gear and filling the rear drawers will sort that.
The most surprising thing besides speed bumps and a few kerb runs is that although its up at least 2" it feels like its lowered - the handling is fantastic, can't wait t go bush !
What an amazing effort Mark, not only that but having me drive you nuts with questions during the install, and Andrew also fantastic to deal with and always ready to give advise ...... Thanks again Guys
lca bushes all freed up and ready for alignment I've got 790 and 840 after only about 20km's , considering adjusting the front up another 5 -8mm just to give a slightly better aesthetic angle once everything settles (have airbag man spring bags in the rear for the Camper trailer) any thoughts ? do this adjustment - test drive, then alignment ?

[drwormy Junior Member Find all posts View Profile Close drwormy]

I installed my rears last night on my FJ, and there were a few things i needed Marks assistance with, so i promised to take photos and write it up.

Firstly, I didnt change springs; just shocks, so that part of the install i didnt cover. In summary, you jack chassis up to wheels off ground (allowing a bit extra as with Ironmans your probably going to have more droop), place on solid jack stands. Take off wheels. Disconnect sway bar links. Place trolley jack under diff pumpkin for support. Disconnect one shock. By pushing down on that side (maybe need a small piston jack between axle and bodymount) remove spring. Replace with new spring. There are now a few options.... connect sway bar and install shock later when back on ground, or install shock now. For the other side, same method, though you might need to jack up on the first spring to make enough room for the new spring. All the while watching for stretched brakelines / handbrake cables.

Shock exchange - you can do this on the ground with wheels on.

1. Remove old shock - undo top shock nut and bottom axle bolt.


2. Install bumpstop rubber like so, then put on cover.




3. Feed in shock, and install bottom bush on axle post. Note the rotation of the shock body. The ring eye is off centre to clear the axle as the Ironmans are so large. Note the spacer washer.




4. Install the small spacer inside the shock bush. Do up the original bolt (just loose is good).




5. I had to go a good cleanup of caked on mud around the body mount. Im using my OEM rear bushes, not the Ironman supplied ones. In the latter case the principle is much the same. Add the bottom part of the bush to the shock, and the locknut (again just loose).




6. Push the shaft up - these are not gas pressured, so wont rise up by themselves. Then using a screwdriver or similar, carefully (and i mean careful to not damage the thread on the shaft) pry the shaft through the body mount. This is MUCH easier to do at ride height (hence why i did it on the ground; otherwise you will need to jack the diff up)






7. Fit top shock bush. I added some rubber grease for good measure. If its clean you should be ok, but it may squeak. Carefully align the bottom bush so the locating washer fits snugly in the body mount. If you dont do this you wont have enough thread to get on the top nut. You may have to slighlty lower the shaft down to fit the top bush over - this is for the FJ, the Prado may or may not have more space in there.




8. Tighten up the top locknut (i prefer to do this with the car on the ground at ride height). Use a 19mm spanner and a smaller (5-6 mm) on top of the shaft to stop it rotating. I use a ratcheting spanner and it makes it much easier. Toyo manual says this should be tightened to 25 Nm - i more went on the compression of the bush. The first few turns can be a bit tricky as the slot in the shaft doesnt appear over the locknut. Here is what the OEM body mount looks like, and the spanners i used.




9. With the car back on the ground and at ride height tighten the bottom eye bolt. For the FJ this should be 98 Nm, and i put some locktite on for good measure.

[FJSA Lurker Find all posts View Profile Close FJSA]

2. Install bumpstop rubber like so, then put on cover.

I installed mine yesterday as well. Similar way to what you described, however I put the rubber bumpstop differently - flat side down. The reason is that the plastic cover has a metal top which is not flat, it's shaped so that the pointy side of the bumstop fits it perfectly. Similarly, it seems logical that when the shock body travels up and hits the bumpstop, it should hit the flat side because the part that contact the bumpstop is flat as well. In summary, when the bumpstop gets squashed we want it to be between surfaces that match the shape of each bumpstop side.

[woodwormm Junior Member Find all posts View Profile Close woodwormm]

Hi Mark, what a phenomenal effort from yourself and Mrs Whitey for this group buy.

As you know through our discussion via emails, I won't be in a position for these foamcells for a couple of years. You'll probably be over spending all your spare time doing these re-valves by then... so just wondering if you'll be sharing the valving setup with (John) Zordo's or if Ironman will be able to valve to your specs for those of us that will be wanting this setup in a year or 2?

Cheers

[Guest Close Guest]

For that bumpstop, I have it opposite as well as per FJSA.

I didn't have the ring spacer/crush tube for the bottom shock mount so I installed it without.