Information Suspension overview: sport springs, sport dampers, coilovers and airride

Hi,

in this thread http://www.a2oc.net/forum/showthread.php?t=6066 the question emerged why to pay so much for a set of aftermarket shocks to get rid of bouncing ride behaviour (and ride harshness).

Sure, the price tag of the recommended Koni FSD shocks has a deterrent effect at first glance. But let’s go a little more into detail.



IMHO a well done suspension upgrade is one of the most effective mods to realise on A2s. However there are several A2 typical given facts that cannot be changed but should be considered during a suspension upgrade:

A) An aluminium body is considerable stiffer both in torsion and bending than regular steel designs of similar shape (same effect with mountain bikes, i.e. rather “soft“ classic chrome-moly steel frame versus „stiff“ oversized aluminium frame).

B) The relatively high A2 centre of gravity.

C) The relatively short wheelbase (short moment arms promote sway motions especially in conjunction with point B.

D) The very differring load between front and rear axle.


As we know the A2 stock suspension setup featuring linear springs (with only little initial sensitivity thus rough initial response) and very weak damping forces does not match the above listed A2 "handicaps“ properly.



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A possible sophisticated (but expensive) A2 supension solution could be a set of custom made springs that features distinctive progressive characteristics. On the one hand this progressive setting would allow

- nice smooth compensation of small to mid size road surface irregularities and
- on the other hand also would prevent bottom out tendencies effectively.


However, because such progressive springs cannot be used safely on A2s without strong damping forces, two features have to be incorporated:

I. a wide-range adjustability of powerful rebound damping with preferably multi-stage performance to match the varying progressive spring rates and

II. a custom fine-tuned compression damping valve.

That special compression valve should be able to mobilise sensitive low- to midspeed response characteristics adressing mainly small road surface imperfections for comfort reasons. At the same time these rather moderate low/mid speed compression (and also rebound) damping forces must still provide enough strength for controlling the comparable small initial spring rate(s) of the progressive springs with authority. So handling capabilities and also roll/pitch motion control must not be affected negatively.

But I suspect this proposed “ideal” custom suspension setup would be very hard to realise :( for our cars since nice handling performance, sound roll/pitch compensation and comfortable/smooth initial response are very difficult to reconcile.



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Because of these above described custom damping/spring tuning related difficulties the mentioned Koni FSD dampers come into play again. Their damping setup turns out to be a compromise between nice balance and comfort especially on less than perfect roads:

1. The FSD compression damping characteristics have been optimised for dealing even with wicked road conditions (no bottom out, no bounce), however at the expense of lowspeed sensitivity. Positive side effects of such rather high compression forces are good handling abilities and reduced pitch and roll motions. So with respect to the compression valving, the FSDs are well suited for progressive type springs up to 35 mm of lowering.

2. The FSD rebound damping, being uniquely triggered mainly by frequency, thus is multi-staged in a special way. In particular with progressive springs unwanted low frequency car body motions (roll/pitch) can develop. The FSDs should have no problem to automatically minimise these 1 Hz body motions by the now stiffened rebound damping force mode. However I presume too weak rebound damping force in combination with progressive springs at certain situations [for example if the high frequency damping mode(= low amplitude rebound force) is activated and the springs at the same time got more or less packed coincidentally]. Then those packed progressive springs, now holding high spring rates, can expand very quickly.



So to fill this FSD-“gap” of lowspeed compression sensitivity depicted in point 1, especially a 15“ wheel solution is indicated. Using that rim size combined with high profile tyres will nicely absorb small road surface irregularities but will not solve bouncing tendencies being mainly based on non-harmonising damping force/spring rate setups.

Finally a list of A2 suitable 15“ wheel sizes with corresponding comfort factors and unsprung mass comments can be found here:

http://www.a2oc.net/forum/showpost.php?p=47169&postcount=19

Cheers
 
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I don't know if this has been covered, but a few of the models in the pics seem to have a 4 spoke steering wheel indicating that perhaps they aren't the sport model. Is the Sport model different in anyway.

Has the Sport model got uprated or lowered springs and dampers or just springs? (never parked next to an Se so i'm not sure about height)

Are the standard sport springs shorter or uprated?
Are the standard Sport model dampers better or uprated more than the Standard dampers, and therefore can be used with lower springs?
Is a basic koni 30mm lowered springs and dampers or any kit better that the sport setup? (apart form coilovers)

thanks
 
I recently had the FSD and Weitec 30mm lowering springs fitted alround. It has undoubtedly improved the ride and helped with the handling/roadholding altho' IMO the latter were pretty good anyway. In hindsight I should have explored fitting ABT springs, with ABt being a more specialised Audi tuner I suspect they may suit better. I would certainly recommend sticking with standard height springs at the rear altho' as yet my dog hasn't complained!

Overall it has certainly taken out the 'crash' effect when driving along Britains potholed highways and byeways, albeit an expensive solution. There are so many variables which impact on the ride/handling/roadholding equation it is difficult to advise other owners unless they have a similar car set up. In other words the improvements to my Sport with 17" wheels and Pirelli tyres will be different to an SE with 15" wheels and say Dunlop tyres.

New tyres will be on the agenda before winter so that will start another round of discussion!
 
I understand, but i'm not sure if the majority of A2 owners that notice ride height and stiffness are talking about converting an SE, where as in my case I have a Sport model, and what is the level of improvement from a simple (say Koni) spring and damper set up (not FSD). And then to further the discussion whether the FSD are that much better than the sport set up?

Its not something i need to do but just future reference
 
...where as in my case I have a Sport model, and what is the level of improvement from a simple (say Koni) spring and damper set up (not FSD).

improvement in handling? or comfort? FSD on A2 mainly solves the harshness issue. At least when I guinea-pig'ed myself to get the FSDs, it was purely to improve comfort. If you want nothing but handling, you get a set of coil overs and fine tune it to what suits you.

...And then to further the discussion whether the FSD are that much better than the sport set up?

Again, better as in better comfort or handling? I'm sure you can get more sporty dampers than FSD for even sharper handling. If you talk about comfort, I can't think of anything worse than the sport apart from track tuned suspension. A real world day to day use, weitec springs, FSD, 16" wheels on at least 195/50 would be a very good balance.
 
Ok sorry,

I thought most people only ever got suspension to improve handling/looks, but after reading the A2 forums I see some try to improve comfort. Sounds like a very weird concept to me (a bit pipe and slippers) lol. If i want a soft ride i wouldn't buy a car that has a harsh ride then try to change it, but each to his own i suppose. :)
 
The problem is a good set up can be firm without being harsh, such as an MG Zed range. Most motoring journo's agree that whatever MGR did wrong in its short life their chassis engineers developed some of the best set-ups on sale in the Zed range. I had a ZT-T which even now outshines just about anything Audi and others can do.

The A2 is harsh, and yet firm would actually deliver a better drive and enable quicker, more enjoyable journey times to be acheived, hence the advantage of FSD's. I also had an Astra T8 with a track day suspension set up and was looking at having a more compliant set up fitted when divorce enforced a sale....:(...sob...

Whatever the skills of Audi they are not the best chassis engineers albeit the A2 is one of their best in the last 20 years until the R8/RS4 of the past year or so. I am comparing with the experience of owning a range of Audis' and other cars ( about 40 in total) over the past 25 years!
 
And then to further the discussion whether the FSD are that much better than the sport set up?

Yep, actually the FSDs are much better in every respect because they unite even better handling than Audis sport setup with much improved comfort. That seems to be contradictory at first sight but it is true.

To make the 17 inch sport wheels alot more pleasant to drive and to eliminate that harshness many German A2 “Sport Edition“ drivers switched to Koni FSD plus either WEITEC, ABT or Audi sport or standard springs. Also Skipton01 for example changed from the harsh (because very underdamped) A2 sport suspension to WEITEC 30/30 + FSD combo being a very effective suspension upgrade.

The results:

  • extreme well overall balance in every situation
  • shorter breaking distance
  • better traction
  • smooth clearing of even severe road damages or sleeping policemen
  • no bottom out and no crashing noises at pothole hits etc.

In hindsight I should have explored fitting ABT springs, with ABt being a more specialised Audi tuner I suspect they may suit better.

The differences between the 35 mm ABT and 30 mm WEITEC springs for A2 are negligible in terms of comfort. Both seem to have similar spring rates and characteristics. So the positive feedback of the German A2 ABT/FSD drivers are more or less equal to the WEITEC/FSD drivers.

Of course the maximum increase of ride comfort can only be achieved with the combination of the Audi standard height springs plus Koni FSD.
 
Sorry if it seems like i am repeating myself. but i don't really understand the replies to my original point. I know the sport is hard/harsh, crashes a bit due to suspension and tyre profile, and who may have the better chassis engineers, and whether it is worse than the many cars people have driven, owned, bought, or sold. All i am really asking is are most of the tests in this thread based on fitting to SE models or fitting to the Sport? And if they are fitted to the SE, is there much variation compared to the Sport.

Sorry if i gave the wrong impression Adrian

and thanks Schnelletrecker
 
EMM, I don't know why you're so obsessed with SE vs Sport model. Forget the rest of the differences in equipment spec., (excluding 1.2) SE/Standard vs Sport A2 differs in the lowered sports springs. So when two cars switch to say, FSD + weitec, there is no difference whether they were sports or SE. If you specifically want to know the effect of FSD+std springs vs FSD+Sports springs, then Schnelletrecker has pretty much given you the idea. And FSD will give better grip regardless of what springs in uneven corners as the wheels stick to the ground more than bouncing from every little bumps.

I thought most people only ever got suspension to improve handling/looks, but after reading the A2 forums I see some try to improve comfort. Sounds like a very weird concept to me (a bit pipe and slippers) lol. If i want a soft ride i wouldn't buy a car that has a harsh ride then try to change it, but each to his own i suppose

I would think most people buy the A2 for the economy, practicality and uniquess and the harsh ride just spoils the overall satisfaction. If I wanted a good handling car for 'sporty' driving, I would have bought an Elise.
 
Below are some pics attached showing the 10 minutes shortening procedure of the yellow PUR-material bump stops:

  • front # 8Z0 412 301 (stock length 75 mm)
  • rear # 6Q0 512 131 B (stock length 122 mm)

This shortening is essential when mounting lowering sport springs such like ABT or WEITEC 30/30 to restore the original residual spring travel value - very important for comfort and safety!

While the rear ones need to be re-glued using low viscosity superglue, the front rubbers simply are shortened from the bottom.

So if fitting sport springs providing 20 mm of lowering net, then the amount of 20 mm of the yellow stoppers have to be removed.
If mounting springs that enable minus 35 mm of car lowering, then 35 mm must be removed per bump stop, etc...

The WEITEC or ABT springs usually get the car 25 to 30 mm lower than stock (the A2 1.4 petrol suffers from its light front unfortunately).





In combination with shocks featuring stock dimensions, e.g. KONI "sport" (= yellow) or KONI FSD, these rubber bump stops can be shortened up to 40 mm maximum.
BUT if these rubbers become shorter than minus 40 mm, the compression valve of the shocks can be damaged potentially due to the piston rod coming in too far! :eek:








However, some A2 folks might ask for a very sporty appearance (i.e. lower than 35 mm and/or front axle lower than rear). If coilovers are not desired (coilovers often require stock length bump stops!) you may go this route for instance: :)

Professionally modified sport springs in combination with shorter sport shocks such like KONI sport “short” (= rebound) or Bilstein B8 assuring sufficient spring pre-load even at minus 55 mm of lowering. Because the piston rod of these shocks is shorter than stock we now can shorten the yellow bump stops beyond 40 mm without risking a smashed compression valve. ;)



Generally the A2 yellow bump stops cannot be combined with the monotube + high pressurised Bilstein B6 and B8 shocks because of the Bilstein typical upside-down design being favourable for low unsprung weight and therefore comfort. They feature integrated bump stops instead and mostly come with an own dirt protection kit.
 
Hi there - I've only just seen the last post about the bump stops. We fitted FSD's a year or two back, but only suffered a broken spring in December. We fitted Weitec 30/30 springs all round as this was Schnelltrecker's recommended route and we decided that while doing one spring we might as well do them all.

I'm not sure though that the garage shortened the bump stops - as I hadn't heard this recommendation before. Is it essential that this is done? Would Weitec have recommended it in their instructions?

If it is, I will have to take the car back in - another bill :(

Edit: I've seen the other posts now that say it is essential. I will ask the garage if it was done!
 
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Well, usually the instruction manual of a set of sport springs contains the remark to shorten the bump stops...

This shortening procedure is no recommendation, it is mandatory in case of any > 20 mm lowering by shorter than stock springs.

Especially the FSD (Frequency Selective Damping) – technology requires free spring travel that must match circa stock value!

If the yellow PUR bump stop rubbers aren't shortened in combination with Koni FSD shocks, the car motion frequency does change significantly due to frequent contacts with these yellow stoppers.

For instance if the boot of a
  • WEITEC 30/30
  • ABT 35/35
  • EIBACH 35/35
  • KW 30/30
  • FK 35/35
  • VOGTLAND 25/25
  • etc
sport springs lowered A2 is loaded with heavy stereo there's virtually no free spring travel left – so the non-shortened yellow bump stops bottom out permanently and a sophisticated spring/damping tuning is gone bust in consequence.
A prominent example for that was EF MAX.


I've seen the other posts

e.g.:

http://www.a2oc.net/forum/showthread.php?p=36420&highlight=bump#post36420
http://www.a2oc.net/forum/showthread.php?p=45498&highlight=bump#post45498
http://www.a2oc.net/forum/showthread.php?p=46338&highlight=bump#post46338
http://www.a2oc.net/forum/showthread.php?p=46529&highlight=bump#post46529
http://www.a2oc.net/forum/showthread.php?p=61483&highlight=bump#post61483
http://www.a2oc.net/forum/showthread.php?p=61491&highlight=bump#post61491
http://www.a2oc.net/forum/showthread.php?p=68877&highlight=bump#post68877



P.S. A couple of German A2s lowered by ABT or WEITEC sport springs first had no shortened bump stops. So after creating more free spring travel (by shortening) more comfort and safety was attained. In your case I would install 4 brand new yellow bumpstops prophylactically since they're prone to disintegrate after some time of frequent “usage”. You could also install new strut bearings...
 
Hi! Thanks for the reply.

We did replace the strut bearings - I had learnt that much from your helpful posts!

However, I have just spoken with the garage - they did NOT shorten the bump stops :(

I will take your suggestion of buying new bump stops and see about getting it done. I hope we haven't done any damage in the month since the springs were fitted? We dont carry heavy loads very often. I should have read more posts before fitting the springs!
 
Below attached are
  • the torque figures to be applied during A2 suspension fitting
  • an illustrated guidance for changing the A2 suspension (made by member A2TDI - sadly only in German)
 
New springs from Weitec?

I visited the weitec.de website today and noticed they state:
30/0 and 30/30 are for the 1,2l
35/0 and 35/30 are for the 1,4l/1,6l (also petrol flavour)

I guess the 35/30 is good news for the discussed high-nose-result of the FSD.

A thing that comes to mind is if the 30/0 (now stated for the 1,2) is also an option for the 1,4 if one would want the better loading capability without getting that much V (nose down) when traveling empty.

Thanks for every informative post about the suspension at the A2OC. That's what make this website a real treasure.
 
Hi,
I hope Schnelletrecker sometimes comes here ...

I read that the H&R springs were very stiff...
I want stiffer front springs, but not "über"-stiff, however, I think the H&R springs may be a good choice for me.
I have a FSI with OpenSky, so not particulary light. My dampers are Koni FSD's.
H&R has 2 models for the A2 : one for the heavy diesels, and one for the petrol engines (1.4 and 1.6). However, the FSI engine is much heavier than the 1.4 (in fact its wight is closer from the diesels than from the 1.4), so the stiffness of these springs might suit my FSI ?

You will say : why not chose another brand ?
well, 1st, the lowering of -25mm is just adequate for me. I don't want more. And 2nd, the H&R springs are black. I don't want a fancy colour. It's not a matter of personal taste, but not to attract attention for our "MOT".

Thanks :)
 
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