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Old 12-04-2013, 05:59 PM   #1
SkiWrex
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'05 Forester XTi
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Default Designing and Building my own strut "Lift Spacers"

I decided that I didn't want to spend $200-$300 for a subtle solutions lift kit. I'd rather just make my own.

Got my degree in design engineering tech. 7 years ago and currently work as a mechanical design/drafter for a medical device company. I spend my day designing/reverse engineering/drawing fixtures, tools, products etc. etc. I figured I could put my skills to use for car parts.

With the onset of winter, I decided that I wanted a little more ground clearance this year without sacrificing the stiffness of aftermarket springs. I didn't want to have to replace the tophate bolts either, so I wanted to just go with a .5" spacer.

I removed a front and rear tophat for measurements, and got my needed dims with a caliper and ruler:



Then I use AutoCAD as sort of a "digital sketchpad" to easily and quickly layout the outline:



Then, I print a 1:1 outline, carefully trim it out with a razor, and then place it on the tophat to test fitment:




Fits good, time to move forward:



Save the outline in AutoCAD, then import it with Solidworks:



Extrude:



Done, ready to send the 3D file to the machine shop:




Currently waiting for our in-house machine shop to make these, I will update with pics when that happens.

BTW, if you have ideas you want put into 3D, PM me a sketch and I'll do it when I have down time.
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Last edited by SkiWrex; 12-04-2013 at 06:04 PM.
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Old 12-04-2013, 06:00 PM   #2
SkiWrex
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reserved for pics.
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Old 12-04-2013, 06:11 PM   #3
Paranoid Fabrications
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hmm, lift spacers. hmmmmm

i would make the inside hole smaller, so it just touches the inside radius of the center. as it will give more surface area and be stronger. also, double check your measurements as normally max size you can fit is 3/8" spacers
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Old 12-04-2013, 06:16 PM   #4
SkiWrex
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Yeah, I would go smaller but there are 3 grooves that protrude up and would cause the spacer to not sit flat, I guess I could mill out a little pocket for them to sit in. It's not costing me anything so I don't care if it doesn't work the first time. 3/8 you say? I will definitely check that.
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Old 12-04-2013, 06:18 PM   #5
Paranoid Fabrications
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not mine, but jackonson rally (i dont make alu ones) but you can see the size difference and the cut out for the groove.
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Old 12-04-2013, 06:28 PM   #6
SkiWrex
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Oh right on. Yeah I think I'll do something like that since I haven't started building these yet.

Subtle just cuts a step in their rear spacer. I think a groove is the way to go:

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Old 12-04-2013, 06:33 PM   #7
PARANOID56
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yea, grove for sure, or why bother even making the hole smaller (ie the subtle ones) the whole idea is to have more surface area on the mating parts.
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Old 12-07-2013, 02:41 AM   #8
Grippen
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Wow. Very nice!
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Old 12-07-2013, 04:01 PM   #9
GDR
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I wanted to be different and spaced out the spring seat instead. Use these with 3/8" top hat spacers and you've got 3/4" total lift on stock studs.



















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Old 12-08-2013, 12:39 AM   #10
PARANOID56
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wont doing that put more preload on the springs? causing them to ride stiffer?
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Old 12-08-2013, 03:22 PM   #11
GDR
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Quote:
Originally Posted by PARANOID56 View Post
wont doing that put more preload on the springs? causing them to ride stiffer?
No, preload does not change spring rate. The only way to change spring rate is to physically change the spring. Changing preload on a suspension only changes sag from it unloaded to loaded height.
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Old 12-12-2013, 10:37 AM   #12
SkiWrex
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that's a pretty cool idea!

I should be getting these machined next week, our machinist has been pretty busy. I'll post pics of it installed.
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Old 12-18-2013, 10:07 PM   #13
Goatcrapp
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Quote:
Originally Posted by GDR View Post
No, preload does not change spring rate. The only way to change spring rate is to physically change the spring. Changing preload on a suspension only changes sag from it unloaded to loaded height.
If it's a progressive spring, preload can compress that initial x distance of travel, making the ride feel stiffer. Non progressive springs, no problem. Just throwing that out there.
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Old 01-23-2014, 01:01 PM   #14
JhnBrackett
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Survey says?
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Old 01-30-2014, 11:09 AM   #15
SkiWrex
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Well, machinist got too busy to build these, so I decided to take a simpler route. I ended up making a washer type spacer (similar to the TIC, Scooby921 spacer) to sit on top of the strut post, right underneath the top hat. I went' .40" on the rears, and .28" on the front. I also put my stock struts with Epic springs back on.




I love it! rides good, little squeaky but I don't give a dam, it's wintermode.

BEFORE


AFTER
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Old 08-05-2018, 12:38 PM   #16
Fran_onix
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Great Work !!

Would you like to share the design? [email protected]

Cheers!
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Old 08-08-2018, 12:16 PM   #17
rtv900
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Quote:
Originally Posted by SkiWrex View Post


Currently waiting for our in-house machine shop to make these, I will update with pics when that happens.
.
since that's just a sandwich plate, a laser shop would buzz out that shape for probably $50, no machining needed.

how are you guys making it?
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