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View Poll Results: Which of these new parts do you want to see in production first?
I want the Subframe Bushings produced ASAP! 1 50.00%
I want the Differential Bushings produced ASAP! 0 0%
I want the Front Control Arm Bearings ASAP! 0 0%
Shutup and take my money, I want them all now! 1 50.00%
Multiple Choice Poll. Voters: 2. You may not vote on this poll

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Old 02-10-2015, 06:27 AM   #1
AllSpeedInnovations
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Default Product Development - 08+ STI Suspension and Drivetrain - Customer Input Welcome!


We are excited to announce a project we have been working on for a few months now. For all you 08+ WRX and STI guys, we have developed several new products to improve the feel and handling of the car. Simply put, if you track your car, if you have lowered your car or if you have been known to tear up some back roads from time to time, these bushings will be exactly what you are looking for!


One of our goals here at All Speed Innovations is to focus our own product line on innovative products. To us, innovation encompasses a couple aspects of product development, improving on products that may already exists or developing new products that solve a problem that has not been addressed. Improving on existing products is easy, we can make a change or add features to make a product better, find new sources for materials or develop manufacturing methods to bring the cost down or we can use engineering analysis to make a product lighter or stronger. Developing completely new products is a much more involved process. This can be approached several ways, but we have found that developing new products based on needs for the motorsport market is the best way to identify and solve existing problems with a specific vehicle. There is no better test for a car than racing it to bring out its flaws. What this means to our customers is that you are getting a product that has been engineered and tested to withstand the rigors of track abuse.

This is exactly how we went about developing the bushings we will be talking about in this article. During the off-season, in preparation for next year, we wanted to make some serious improvements to one of our track cars, in this case, Shelby's 08 STI. In our opinion, this model has been seriously neglected in the area of suspension development. Sure, there are some bushings, sway bars and various suspension arms out there, but there is no one that produces a complete package and no one that addresses some major concerns with the suspension setup. We intend to change that with these parts and several others we are working on!

As will any of our products, the first step in development is defining the problem. Once a problem is defined, the real fun begins as we determine several solutions for the problem that may work. We then spend time in design using Solidworks and where necessary, stress analysis and optimization to improve performance and reduce weight. The end product is a design concept as shown below that we then manufacture for prototype and testing. This is where we are today on these new products.


We hope that this thread will be informative for those people interested in how we develop a product, as well as for those customers interested in improving the handling and feel of their car.

Pricing for all of these parts has not yet been finalized and neither has the order for releasing the production versions.

If anyone has any questions about the products or has a strong desire to get one of these products in their hands ASAP feel free to comment, call us or email support@allspeedinnovations.com. This thread is completely open for questions, concerns or suggestions so that we make sure we do not miss anything our customers want!

Don't forget to participate in the poll above to help us finalize our production schedule!


We will update this thread with any more development work on these parts and let people know when we will be taking orders.
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Old 02-10-2015, 06:29 AM   #2
AllSpeedInnovations
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Geometry Correcting Sub-frame Bushings

One major concern with the 08+ STI is the lack of options for the rear sub-frame, the problem being, a complete sub-frame replacement is expensive and out of the realm of possibility for a lot of people. So what can be done with the existing frame to improve the car? The simple answer is to improve rigidity and geometry. The 08+ sub frame is remarkably more stiff the previous generation and there is not much that can be done in this aspect to make improvements. When it comes to geometry, there is room for improvement. When lowering the 08+ STI, the geometry of the rear suspension changes, meaning the angle of the rear control arms, this effectively lowers the rear roll center.

That's good right? Lower is better! Well not really!

Without boring you with too much detail, the roll center is the point around which the vehicle wants to roll, the location of the front and rear roll centers determines the roll axis of the vehicle. The relative location of the center of gravity to the roll center impacts how much the vehicle will want to roll. Think of when you are trying to break a suborn bolt free, you might not be able to rotate the bolt with a standard breaker bar, you just can't create enough torque. Add a cheater bar to the end and the bolt breaks free, you were applying the same force but your torque arm was longer creating more torque at the bolt. The same concept can apply to the suspension, the further your center of gravity is from the roll center, the easier it is for the car to roll in a corner, that is a bad thing!


Lets go back to the STI, when you lower the car, your center of gravity moves down, but so does your roll center. The only way to improve the situation and reduce body roll is to raise the roll center closer to the center of gravity. Doing this in the rear combined with a quality front roll center kit will result in improved cornering and allow less body roll. Less body roll in the rear of the WRX and STI means less suspension movement and less toe misalignment in corners (An entirely different issue with the rear suspension geometry on the 08+ chassis). So lets take a look at how to solve this problem.

The simple solution is a new sub-frame with adjusted control arm mounting locations, we already mentioned the price hurdle there. The next best bet is to raise the rear sub-frame thus raising the control arm mounting locations. This may seem difficult, but for anyone who has seen the rear sub-frame bushings, you know there is a 3/8 inch gap between the car and the actual sub-frame. None of the existing bushings or bushing inserts address this issue as you can see!


Our solution was quite simple, create a busing that moves the sub-frame as high as possible. This process was accomplished by removing the upper bushing flange such that when the bushing is installed the top of the bushing is flush with the top of the sub-frame. The nice thing that Subaru did was to include retention plates on the top of the sub-frame bushings that, in factory configuration, limit the amount of flex allowed by the factory bushings. These plates provide us with a clamping device that supplements the press fit of our bushings making the sub-frame mounting completely rigid and eliminating any possibility of the bushing slipping under load!


We spent some time optimizing the bushings to reduce the weight without sacrificing strength, obviously, a large chunk of aluminum would be pretty heavy. On the prototype we were able to come within 4 ounces of the popular polyurethane bushing kits and we see some more room to make up the weight difference when we move into production machining!

Installation of the sub-frame bushings, once the sub-frame is out of the car is quite simple. Heating the frame and freezing the bushings allows them to be pressed in with reasonable force and once temperatures equalize, the bushings are securely fit to the sub-frame with a mechanical press fit. Subaru is not too concerned with tight tolerances in these locations so some customers may find the need to lightly massage the inner surface of the frame with a sanding drum but we always shoot for tight rather than loose in this application and we have measures in place once in production to help anyone that may have a frame that was built on Friday that is way out of spec.


The next phase of our development process is to get the frame back in the car for testing and develop our install documentation. We will then be ready to move into production.
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Last edited by AllSpeedInnovations; 02-10-2015 at 10:57 AM.
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Old 02-10-2015, 06:29 AM   #3
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Solid Differential Bushings

While we were addressing rigidity in the rear of the car, we wanted to improve mounting for the rear differential. There are plenty of options out there already including poly bushings and poly inserts. In our experience the inserts tend to offer very little bang for your buck and do not really do much at all. We have a hard time recommending them as a product we would use. Sure they are inexpensive and easy to install, but for someone wanting the tightest mounting solution they are simply not the answer. On the other hand, the poly bushing replacement kits on the market work well, for most customers they are a great compromise between a sturdy mounting solution and noise levels and the prices are still reasonable. The install can be more of a pain in the ass, but the improvement in response from the rear differential is well worth it. We decided to take things one step further with our solid aluminum rear differential bushing kit.


Our aluminum differential bushings are designed to be direct replacements for the rear differential front and rear factory bushings. Designed for those customers who really beat on their car or love to take it to the track. If you like to hear your car work and desire the best feel and feedback, these bushings will be exactly what you want. You can expect improved feel and instant response with minimal noise increase from a solid poly bushing (we really do not think it is that loud anyway). Sure they will not be for everyone, if you are very concerned about noise, stick to the inserts. If you think you can handle the solid poly bushings, we suggest you give these some thought as well. They eliminate all movement of the rear differential and eliminate any of the maintenance requirements of poly bushings.

Installation for the prototype set was as simple as applying some heat, freezing the bushing and popping them in resulting in a perfect press fit after temperature equalized between the parts.


The prototype set of bushings (both front and rear combined) came in at 10.2 ounces heavier than their poly counterparts and as you can see there is plenty of room for improvements. We did not spend much time with weight reduction to keep prototype costs down (fewer machining operations) because we already knew from our simulation that they would be so close. Moving forward, we will be continuing testing and then optimizing the design to get some weight out, we fully expect these parts to come in under the weight of the full poly replacements. Once the weight optimization is complete we will be ready to move into production and finalize our install documentation.

That completes the rear of the car for now, we are working on several other parts to address the rear suspension and drive train that will come at a later time, but we only have so much time to work on development work right now.
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Old 02-10-2015, 06:30 AM   #4
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Front Control Arm Bearing

This brings us to the front of the car. The front of the 08+ cars is different than the rear in that there is not much going on and there is a lot of aftermarket support. Great options exist for the roll center adjustment, anti lift and sway bars even for the motorsport crowd. There was one spot that was lacking though! The front control arm front bushing. There is simply no a good aftermarket solution. The poly bushings out there work and fit but customers complain of noise and bushing degradation. Quite simply, the poly bushings cant take the abuse.

Take a look at a common poly bushing install in the front control arm on the 08+ STI, the bushing takes up the space between the arm and the sub-frame and rubs back and forth constantly resulting in wear and if not properly lubricated, noise. The noise is caused by the bushing binding as the arm moves. This is less than idea and makes your damper and spring work even harder to control the movement of the wheel which in extreme cases could result in odd handling.


Again, our solution is quite simple, a spherical bearing replacement that eliminates any possibility for bushing binding. This tried and tested method would be sure to create a robust solution that functions properly, but there are challenges in this application. Subaru does not seem to care much about the tolerances of their bore diameter or width of the arm, this makes sense because they are pressing in a rubber bushing that will deform as needed. With a spherical bearing, you need precise tolerance so that the bearing can be pressed in and not move without having too much crush preventing the inner ball from moving freely. This created some design challenges.

Many companies that make similar parts for other cars use a full length sleeve that they press into the control arm and secure with a large c-clip. We felt there was too much variation in the OEM part for this kind of solution so we started down a different path. Creating a two sided sleeve would compensate for any variation in the width of the control arm (like with the poly bushings), but to do this properly, we would need a way to retain the bushing sleeve in the arm. Normally the press fit would be enough but as we mentioned Subaru does not control the bore with enough precision to trust just the press fit. In response to this we developed a through bolt clamping method to securely sandwich the OEM arm within the bearing sleeve. This prevents any movement of the sleeve and accounts for the poor OEM tolerance without the need for the bearing sleeve to contact the sub-frame as in the picture above which would defeat the purpose of using a spherical bearing in the first place.


With the outer sleeve being secured and taking care of the poor OEM tolerance, we could machine the inner bore of our sleeve for the perfect press fit of the actual spherical bearing. Some companies may look to china for sourcing a bearing, but that does not really fit our plan so we selected the largest size bearing we could fit from one of the best bearing manufacturers here in the states. It adds some cost, but we think it will be well worth the expense when it comes to the longevity of the bearing. Of course the bearing is of low maintenance Teflon lined construction for long life.

Installation of the parts is not too difficult, again the heating and freezing method works well. The arm is heated and one side of the bearing sleeve is cooled and they press together without much difficulty. Then once installed, the spherical bearing is cooled while the installed sleeve is heated and the bearing is pressed into the installed half of the sleeve. Next, the other half of the sleeve is installed, first the through bolts are aligned and started so that the bushings remain aligned properly, the arm is heated and the second half is pressed in finally being secured by tightening the bolts to lock everything in place.




The install process for these bearings is a bit more complex than normal, but we feel that the results and reliability of the product are well worth it. The last step is to install the bearing spacers that locate the arm properly within the sub-frame similar to any of the coilover kits that use spherical bearings for the lower mounts. These spacers slide easily into the sub-frame and the sub-frame is clamped around them with the OEM bolt.


The final step for the front control arm bearings is to test fit the design on several arms and refine the install process to make it easier for customers. At that time we will be ready to move these parts into production!
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Old 02-10-2015, 06:30 AM   #5
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Additional Pictures













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Last edited by AllSpeedInnovations; 04-15-2015 at 10:37 PM.
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Old 02-12-2015, 02:09 AM   #6
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We went ahead and installed the rear Differential and the fitment is great. We will be making a couple small adjustments to the flange thicknesses on both the front and rear diff bushings for the first production run along with tightening up the bolt holes a bit to dial everything in.

The Subframe will go back in on Friday so you guys can see what the sub-frame bushings actually do.

We are still looking for input from people so feel free to chime in and ask any questions or participate in the above pole.

Here are a couple pics:





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Last edited by AllSpeedInnovations; 04-15-2015 at 10:40 PM.
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Old 02-13-2015, 12:45 PM   #7
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We went ahead and installed the front control arm bearings today. A couple changes will be made to help out with the install but the fitment was really nice. They will go on later today along with the sub-frame.



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Old 02-13-2015, 09:09 PM   #8
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We just finished up reinstalling the sub-frame with the new bushings and wanted to throw up some pictures for everyone to see exactly what is going on with these.

Here you can see the new bushings stop flush with the top of the sub-frame:


The retention plates that were mentioned in the fist post are then reinstalled on top. These plates are intended to limit the movement of the frame when the soft stock bushings are in place. In our case, they are uses as a fail safe should something happen with the bushing and will prevent the frame from moving up at all although with the amount of press fit we designed into the bushings its really a non issue.


And here it is back in the car, you can also see the solid rear diff bushings:


Next we have a close up of the retention plates sandwiched between the chassis and the sub-frame, not much will be moving here:


This last picture shows exactly how far up we were able to move the frame (See post one for why this is a good thing), the extra material hanging down is used to take up the extra length of the OEM bolts. In the front the stock braces will need to be reused, in the rear we will be supplying washers for under the bolt heads because the stock plates that were used to support the OEM bushings look pretty terrible with all the space there and the flange on the bushing is plenty to hold everything tightly in place:


That is about it for now in the rear of the car. We will be finishing up the install of the front control arm bearings tomorrow. In the meantime, we would be interested to hear peoples thoughts, questions, concerns etc.

Please be sure to vote up top so we know which ones, if not all of them to move to the head of the production line.

Next up for these rear bushings is test fitment on a second car for verification before we put these parts into production!
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Old 02-19-2015, 09:44 AM   #9
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We went ahead and installed the front control arm bearings on our car. We will be making a couple changes with these to help people with install because with the way they are now it is kind of a pain to do.

Otherwise the install went great, and fitment was awesome. Here is a shot of the bearing installed:


Feel free to chime in with any questions!
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Old 02-25-2015, 09:39 AM   #10
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Bump for some feedback! Pricing will be announced a week from Friday and we will work on getting the pre-order group buy going!
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Old 04-15-2015, 11:13 PM   #11
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Just a quick update on these, we will be testing the current designs on our car next month on track to make sure they can take the beating. In the meantime, we are working on pricing and tooling up for production on our Haas.

We will post pricing once we are happy with the test results on the track car.
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Old 04-16-2015, 12:04 PM   #12
mitch808
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2002 Subaru WRX

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'Cause race car!

Curious how bad these would be on the street... But I have to say, you guys did a killer job, I'm actually really impressed with the front control arm bearing solution.
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Old 04-16-2015, 12:20 PM   #13
AllSpeedInnovations
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Location: Lebanon, OH
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Quote:
Originally Posted by mitch808 View Post
'Cause race car!

Curious how bad these would be on the street... But I have to say, you guys did a killer job, I'm actually really impressed with the front control arm bearing solution.
We don't expect them to be much worse than the current solid poly options, those already create a good amount of noise, but we will know more soon and post out thoughts once we finish testing. There may be a bit more noise from the diff but I doubt it will be much!

Thanks for the complements on the designs!
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