Sorry for the wait, I've been pretty busy.
Since I don't have many pictures during the install, I'll try to describe it as best I can... I'll be using some photos from the racinjitter's SERIAL9 install found http://www.zcar.com/forums/read/2/2006740, since I don't have photos to illustrate some things.
This install is very similar to the Arizona Z car coilover install found here:
http://www.arizonazcar.com/coilover.html
Some thoughts first:
I originally used DC2 Integra coilovers, but they dumped the car undriveably low. If you do some research and measurements, you won't need to use s13 coilovers. As long as the perches are 2" ID, you can use them. I thought about using the serial9 perches, but they are just ridiculously expensive.
I apologize for the crappy write up, but I didn't think to take pictures. BUT, it's very straightforward and if you can use you head you'll figure it out.
(NOTE: when I say "perches", I am referring to the sleeve perches on the coilovers, NOT the ground-control type ring perch).
What you'll need:
4x s13 coilovers with 2" ID on the lower sleeve perches, I used EMUSA coilovers
2x extra front perches, since the rears of the s13 coils are most likely going to be aluminum, and you need steel perches.
These are teh exact coilovers I bought:
"Special" Tools:
Sawzall or sawing tool
Dremel or similar tool
Access to hydraulic press
Access to welder (optional)
That's it!
Process:
1. Prep the coilovers you just bought:
- Remove lower perches
- Toss out rear perches, you won't need them since you have 4 fronts.
- You can choose to cut off the s13 mounting brackets, but you don't have to. They don't get in the way on the Z.
- Measure how much smooth tubing is inside the perches, from the bottom, before the threads start. This is how much of the Z strut tube you'll want to keep when chopping the Z struts.
- Cut a notch in 2 of the perches, to accommodate the notch on the spindle that prevents the perch from sitting flush on the hub spindle.
- Remove top hats, you won't need them
- Re-use the top washer and one of the bushings from the top hats, and install as shown:
Done!
2. Dissassemble your strut/hut assemblies. Disassemble top hats.
3. Chop off your Z struts, keeping 1-2" of strut tube left depending on your previous measurements of the coilover perches.
4. PRESS on 4 front perches onto the remaining section of tube. This will be a VERY tight fit, so you'll need a press. Press it on all the way.
Serial 9 perch being pressed on, press on all the way to the base of the spindle:
5. After pressing, you can choose to weld the connection if you want. I don't think you have to, since it's a very tight fit and should hold with the weight of the car.
6. Thread on coilover bodies onto the perches.
7. Grind out the notch in the Z top hats where the shock passes through. You'll see it. Grind it so that the coilovers can pass through.
8. Slide top hats on.
9. Re-use the coilover top nuts
10. Re-assemble everything.
11. Zip-tie brake lines onto coilover body (ghetto but it works for me)
12. Set ride height and preload.
Some of my photos:
NOTE: These pictures are when I DIDNT weld or press on the perches all the way yet. These were just test fits! The weld-looking stuff in the pictures is just goop!
NOTE2: The base of my perches have black spray paint on them
The ride isn't terribly bad. You can use softer springs if you want more comfort. Just press on the perches to 1-2" of strut tube, and press them on all the way to the base of the spindle, and weld.
For anyone who says this install looks ghetto, you can do a much cleaner job if you spend a bit more time on it and pretty it up. It's very simple. It's not much different from sectioning struts, except this time you're cutting most of the strut off and pressing on the s13 coilovers.