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The Zappo Build


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#201 Zappo

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Posted 28 January 2012 - 05:42 AM

New racing season starts soon, so time to update the car. :)

I picked up a set of D2 coilovers a few weeks ago and finally got them installed over the weekend after snow delay. Today I had the car corner balanced and aligned.

I decided to go with the D2s for a few reasons.
First of all I was looking for something that would give me camber adjustment.
Second, I wanted something that used a standard coilover spring, so if I wanted to change rates I can. KW doesn't offer either of these. The rears of the D2 don't use a standard spring, but it doesn't look hard to modify the upper mount on the car to accept one.
Third, the cost is hard to beat.

Finally, I wanted to test them with racing stress. Most of the people that are using them on VS right now are more about stance and slamming the car; neither of which I am interested in. Most have seen the one dramatic failure on here, but it seems like an isolated issue given how many people are using them now and for how long.
Anyway, I will put some high cornering stress on them to see how well they hold up. I might be praising them or cursing them and looking for something new in 3-4 months. :)

Initial impression is they are stiff, even at the softest setting. Ride wise it isn't as bad as I expected though. You feel a lot more of the little stuff, but the sharp bumps at freeway speed are actually less noticable than with the Weitec setup I had before. I may change the springs at some point to soften it up given the car is also my daily, but I will live with it now.

Brian (68123GT), now with TC Motorsports, just finished up the corner balance and alignment on the car. He said the D2s are much stiffer than the KWs he has on his yellow, or they were when he first drove my car. He eliminated all the preload on the springs and said it felt better. KWs use a progressive spring, or two springs at different rates on the front coilovers, so it probably does ride better.
As soon as I have the weight numbers I will post them up. Was looking to get -2 degrees on the camber, but Brian said one side maxed out at -1.1, so he set both to that. Looks like my subframe bushings are to blame for the frame shifting a little, so I guess its time to go Delrin.

Haven't really had the chance to test it out, but I did take a few corners and I can tell there is an improvement on speed. In fact, I could have gone faster. I would have been maxed with the old setup, but this seemed to handle it easily. Also, the car seems to react faster in a straight line when applying power; I am assuming due to less suspension give.

Ride height is slightly lower than what I had before. No pictures of that yet. Car is filthy and I am going to wash before photos. I do have pics of the front coilovers in the car and will take some pictures of the rear also. I am using them as documentation that the suspension was installed correctly in case of any warranty issues. I am also using the D2 endlinks instead of the QBM ones for the same reason.
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#202 B Mac

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Posted 28 January 2012 - 02:51 PM

Nice to hear they're being used for their intended purpose! Are you still using the IPD front bar or did you put the oem bar back on?

The name's Ben: '95 850, m56 w/ gripper lsd, Sachs 707 pressure plate w/ organic disc, built '02 RN 2.3L, worked '04 R head, Enem Y21 cams, Precision 5857B, ARD tune, blah blah blah
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#203 Zappo

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Posted 28 January 2012 - 04:34 PM

IPD in the front. I have a 28mm bar in the rear. If their coilovers won't work with other aftermarket parts, they shouldn't be building coilovers in the first place. :)

I do still have the front OEM bar.

There is a warranty card you need to fill out in the back of the install instructions, but they don't give you an address to mail it to. They also need to hire someone with a better grasp of the English language to reword the instructions and fix the many spelling mistakes.
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#204 Kevin.

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Posted 28 January 2012 - 06:24 PM

I see you're using TT, but have you considered having Lucky tune your car since he's so close to you? Might fix many of your problems and headaches

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#205 Zappo

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Posted 28 January 2012 - 07:09 PM

I see you're using TT, but have you considered having Lucky tune your car since he's so close to you? Might fix many of your problems and headaches

Obviously, you haven't read very far. Most of my problems were solved by changing injectors.
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#206 Kevin.

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Posted 28 January 2012 - 07:12 PM

Well I saw that, just wondering if you had considered getting an ARD tune yet

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#207 lookforjoe

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Posted 28 January 2012 - 10:34 PM

I'd like to see pics of your suspension install when you get to it.

I may go with Kalpenke's front setup to go with the rear I already bought. It's going to be a busy spring for me!

VSXCsig3a_zps930bdcd1.jpg
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#208 MattyM

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Posted 30 January 2012 - 12:38 AM

This is a sweet build! I plan on doing something similiar to this once i get my 850 turbo. Keep up the great work!

#209 Zappo

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Posted 30 January 2012 - 12:43 AM

I'd like to see pics of your suspension install when you get to it.

I may go with Kalpenke's front setup to go with the rear I already bought. It's going to be a busy spring for me!

I thought about going that way also since his setup has everything I was looking for. Only drawback is it is double the cost, but would never have an issue with it construction wise.
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#210 Zappo

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Posted 02 February 2012 - 07:03 PM

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Just a quick photo this morning of the 18s on with new ride height.

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#211 lookforjoe

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Posted 03 February 2012 - 02:16 AM

^ Lookin' Good!!

VSXCsig3a_zps930bdcd1.jpg
1998 V70 XR M66 PTE6262 BB Built '04 2.3l Block Wiseco Pistons 147mm H-Beams '03 Ported Head EnemY21Cams TurboTuner 710cc Inj, DW300, 3" DP back Dual Magnaflow 14834's Apr 2013 408WHP AWD (@7925rpm) 347WTq(@4400rpm)@18psi LGSpeed Header Custom Intake Manifold 30x12.5x3.5"Treadstone FMIC Spec Stage III+ SO603FS Kaplhenke CoilOvers


#212 Zappo

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Posted 03 February 2012 - 03:40 AM

Now if I could find the time to wash it. :)
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#213 B Mac

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Posted 03 February 2012 - 03:49 AM

Dear George,

I hate you.

Sincerely,
Ben

PS: give me your wheels please
PPS: give me your brakes too :ph34r:

Just a quick photo this morning of the 18s on with new ride height.

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Edited by B Mac, 03 February 2012 - 03:50 AM.

The name's Ben: '95 850, m56 w/ gripper lsd, Sachs 707 pressure plate w/ organic disc, built '02 RN 2.3L, worked '04 R head, Enem Y21 cams, Precision 5857B, ARD tune, blah blah blah
Big Will:your car is the most raw, awesome Volvo I've ever driven....mine is just shinier
Wingnut: Of course jewfro vs. gingerbreadman wrestling is mandatory entertainment.


#214 AdirondackVolvo

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Posted 04 February 2012 - 07:39 PM

Those wheels look sweet on there.

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#215 Zappo

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Posted 13 February 2012 - 11:22 PM

Update on the coilvoers after my first autocross event from Saturday. Everything went well, but I haven't examined them closely for any damage, but right now I don't expect any. I could definately feel the cornering difference, even though I didn't have as much negative camber as I wanted. Car wants to turn in much better, but part of that could be from the competition alignment and corner blanace I had done.
Quite happy with the results so far. Did have the shock settings all wrong in the front; one was full soft and one was full stiff. :lol: In the wet I am sure it was causing some understeer turning right, but that went away as it started to dry up. I didn't actually notice it was wrong until this morning when I reset it. The new setting is much nicer on the street when running my 225/40/18 tires. So, so far so good.

Due to some subframe bushing issues, -1.1 is the most camber I can get right now The car will align correctly, but one side maxes out at -1.1. I have ordered some Delrin bushings that should help center up the subframe again and also stiffen it up. I will have a review on the Delrin's when I get them installed.
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#216 Jesus

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Posted 14 February 2012 - 02:18 PM

Glad to hear that your liking them.Surprised that they're stiffer than KWs.

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#217 Zappo

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Posted 14 February 2012 - 02:23 PM

Glad to hear that your liking them.Surprised that they're stiffer than KWs.

Well, I am not sure they are now because as I said above, i had one set wrong. However, KWs are a two spring design up front, so there is a smaller helper spring that would improve the ride quality.
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#218 volvo

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Posted 14 February 2012 - 05:03 PM

Well, I am not sure they are now because as I said above, i had one set wrong. However, KWs are a two spring design up front, so there is a smaller helper spring that would improve the ride quality.


One of the benefits, though few, of the KW's ..

but at the price of the D2's they are hard to beat,

im glad a lot of members on here have chosen to give us feedback because its most likely the next major purchase for this vehicle i will be making,

PS HellaStance on that bishh

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#219 Zappo

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Posted 05 March 2012 - 05:58 PM

Latest update.

Over the weekend I installed delrin subframe bushings to replace the stock ones.

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They are pretty much like this picture, although the design has changed a little and the aluminum plates are no longer used. The stock bushings are rubber in a plastic sleeve with a steel tube in the center. They are pressed in and not all that easy to remove. I can post up my removal process if anyone is interested. It will destroy the old bushings though. Installing these is 5 seconds for each one.

Right away I noticed more vibration at idle, but it is only at idle. Even at 1000 RPM the vibration goes away. I believe most of this vibration is actually from the bushing I used for my transmission mount. I might run a test in a few days to confirm this and if it is true, I do have a slightly softer one I can use to see if it makes a difference. I already had a vibration at idle before I swaped in the delrins, so that is why I think it is the trans mount. The vibration got worse after the swap, but that means the stock bushings were absorbing it. It also means they were flexing more. I don't notice any vibration beyond idle and it doesn't seem to make a difference in my ride quality, but again, my suspension is a lot stiffer than stock now.
Driving seems fine and it does feel like the car reacts better. I mostly installed them to try and center the subframe better to get a bit more negative camber out of the camber plates. I will be autocrossing both days this weekend and that will be the real test. They can be purchased here, http://yother.com/cj...-brakes-02.html if anyone is interested. I will post again after the weekend to see how they work out.

I also installed this,
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Zeitronix Black Box. Now I don't need the laptop in the car to log, which means I can log during track days and autocross without having to come up with a way of mounting the laptop securely. I tested it out and it is working great, except for the lack of a way to set the RPM signal correctly. It just records the raw data, so I have to multiply the number I see x4 to get the correct RPM. Yes, 4 and not 5. The stock tach is a 4 cylinder tachometer and the ECU alters the signal to it to compensate for 5 cylinders. There are no 5 cylinder tachs. :) Already used it to alter my current tune twice.
Really easy to use, just push the button start logging and push it again to stop. The SD card allows for hours of logging.
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#220 gmsgltr

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Posted 05 March 2012 - 06:41 PM

thats awesome! ^^^^ i think a friend has this on a turbo rx7 he races around haha

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