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Workshop Note - Bump Stop assists #626280
27/03/20 03:46 PM
27/03/20 03:46 PM
Joined: Dec 2008
Posts: 18,435
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
Roadster Guru
Member of the Inner Circle

Joined: Dec 2008
Posts: 18,435
South Yorkshire
This week I finally found time to fit Roger's bump stop assists to my Roadster.

The axle travel was easy to measure. If you recall, after I fitted my replacement wooden tool tray, the axle breather punched a hole in it, which was near as dammit perfectly round.

I opened this up and fitted a plastic cover.........so now the breather slides into the plastic cylinder on full deflection, to the extent that all the paint has been worn away from the breather cap. Quite some achievement!

The travel on my Roadster from static to full deflection is 52mm.

So..........You've all seen Roger's masterpiece of design.

[Linked Image]

While doing this, I held the hood frame up using a long elastic strap, like so........

[Linked Image]

This is just a reminder of my first replacement wooden tool tray and what it can carry.......all wrapped to reduce rattles. Wood is a satisfying way to make a tool tray and now we all have time to spare, why not give it a go? This one dates from about 2010, and remains sound.

[Linked Image]

This image shows the nearside. Space is tight and this bracket was incredibly fiddly to fit without removing the damper, but I managed it in the end. To the right of the bracket is the master fuse.
You will also see two blocks of wood screwed to the frame. These blocks don't appear to do anything. I've left them in place, but their purpose remains a mystery.

[Linked Image]

And with the bump stop fitted. I set the initial gap at 45mm. Roger recommends starting wide, and reducing after a few test drives. No idea when I might be doing a test drive right now...........
The giveaway will be the witness mark on the top of the leaf spring. I could also repaint the breather cap and see if the paint remains intact!

[Linked Image]

Offside was much less fiddly to fit. Here you can see how the paint has been removed from the breather cap............... thumbs

[Linked Image]


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) AR Plus 4
Re: Workshop Note - Bump Stop assists [Re: DaveW] #626290
27/03/20 04:16 PM
27/03/20 04:16 PM
Joined: Jul 2007
Posts: 16,132
Suffolk
John V6 Online content
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John V6  Online Content
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Joined: Jul 2007
Posts: 16,132
Suffolk
I still need to fit mine as I found the n/s difficult, I have an idea how to do that & will try soon. I also thought that if you jack the car up on the diff then you could set the height to full travel & let them down a little.


JohnV6
2006 Indigo Blue Roadster S1
Re: Workshop Note - Bump Stop assists [Re: DaveW] #626291
27/03/20 04:20 PM
27/03/20 04:20 PM
Joined: Dec 2008
Posts: 18,435
South Yorkshire
DaveW Offline OP
Roadster Guru
DaveW  Offline OP
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South Yorkshire
No John, if you jack the diff, you get the same height as with wheels on the ground……..


DaveW
2005 Corsa Red Roadster S1
2016 Saffron Yellow (Narrow) AR Plus 4
Re: Workshop Note - Bump Stop assists [Re: DaveW] #626338
27/03/20 06:59 PM
27/03/20 06:59 PM
Joined: Aug 2014
Posts: 618
Northern Germany
bmgermany Offline
Talk Morgan Regular
bmgermany  Offline
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Joined: Aug 2014
Posts: 618
Northern Germany
A tip: The assembly becomes a little easier if the nut is fixed first (a little) on the lower clamps.
In this case you can still turn the bumper holder a little to fix the upper clamp...


2005 4/4 1800ccm Duratec and a lot of HONDA CX500.......
Re: Workshop Note - Bump Stop assists [Re: DaveW] #626394
27/03/20 10:07 PM
27/03/20 10:07 PM
Joined: Oct 2007
Posts: 195
Sandhurst, Berks
T
teknome Offline
L - Learner Plates On
teknome  Offline
L - Learner Plates On
T

Joined: Oct 2007
Posts: 195
Sandhurst, Berks
I fitted the bump stops to my Plus 4 a few months ago, I could not get the gap between stop and spring to be less than 40mm. Roger supplied a pair of stops with longer bolts (the bolt that is bonded to the stop). Currently awaiting a bit of normality so we can go on an extended road test.


---------------------------
Mike Smith


1995 +8
2007 +4
Re: Workshop Note - Bump Stop assists [Re: DaveW] #626871
30/03/20 10:55 AM
30/03/20 10:55 AM
Joined: Dec 2014
Posts: 146
P
PHZI Offline
L - Learner Plates On
PHZI  Offline
L - Learner Plates On
P

Joined: Dec 2014
Posts: 146
Great bits of kit. I fitted mine to the Plus 8 about 6 mths ago; no real problems. I cut a piece of timber to the required length which was an easy method to set equal heights on both sides.

Crikey! The things you find time to write about during Lockdown! :

Re: Workshop Note - Bump Stop assists [Re: DaveW] #628422
05/04/20 03:07 PM
05/04/20 03:07 PM
Joined: Jul 2007
Posts: 16,132
Suffolk
John V6 Online content
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John V6  Online Content
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Suffolk
Fitted mine today. I found the passenger side very fiddly. with fat fingers the gaps weren't big to get in at the nuts.
They are set at 35 mm for now. The short drive to the shops Monday should help define if they are set well.
That is if my back is OK on Monday!!


JohnV6
2006 Indigo Blue Roadster S1
Re: Workshop Note - Bump Stop assists [Re: DaveW] #628462
05/04/20 06:00 PM
05/04/20 06:00 PM
Joined: May 2012
Posts: 983
Sumerset
Rog Offline
Talk Morgan Regular
Rog  Offline
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Joined: May 2012
Posts: 983
Sumerset
Well done John. That side is a bit tight hide

35mm above the springs should hopefully give you some useful spring assist….. smile


Roger
2011 Plus 4
Re: Workshop Note - Bump Stop assists [Re: DaveW] #628464
05/04/20 06:05 PM
05/04/20 06:05 PM
Joined: Jul 2007
Posts: 16,132
Suffolk
John V6 Online content
Member of the Inner Circle
John V6  Online Content
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Joined: Jul 2007
Posts: 16,132
Suffolk
Hope so Rog. I also found that the hoop was parallel to the back board for the woodwork so that side was tighter.


JohnV6
2006 Indigo Blue Roadster S1
Re: Workshop Note - Bump Stop assists [Re: DaveW] #628880
07/04/20 01:27 PM
07/04/20 01:27 PM
Joined: Jul 2007
Posts: 16,132
Suffolk
John V6 Online content
Member of the Inner Circle
John V6  Online Content
Member of the Inner Circle

Joined: Jul 2007
Posts: 16,132
Suffolk
Today I took the car out of the garage to take off & clean the rear wheels.
I took the chance to grease the cart springs & waxoyl as well.

But wrt the stops there was no obvious witness marks from my one short trip. I left them for now as they are given the restrictions.

I can though give you one extra fitting tip.The bottom clamp is difficult to get at from above. With the wheels off there is a nice gap under the plywood wheel arch. It is really easy then to get a spanner in. If I were to do this again I would take the wheels off.


JohnV6
2006 Indigo Blue Roadster S1
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