Finally got the suspension in. This was my first time doing major suspension work, and it took the better part of the day to get it all done. Here are a few lessons learned for anyone else looking for the Old Man Emu kit (or any similar kit).
As another forum poster put it, the factory leaf springs are made from recycled marshmallows. I broke a spring about a month ago and stuffed it back in the pack with a hose clamp. It held in place but it was asking for trouble down the line:
Taking some advice from members at thenewx.org, I modified my leaf packs a bit to try to reduce noise in the future. The Dakar set is known for popping and clunking, especially once they get some dirt and rust between the stack.
I put galvanized lumber ties between each leaf except the overloads. This makes the springs only touch at the center and the tips, creating less friction along the length.
I also wrapped the retainer brackets with heavy duty shrink wrap. This keeps the packs closer together to try to limit noise from movement.
I did the front spring work myself, and it was very time consuming. I read about a guy breaking a heavy duty wall mounted spring compressor with the OME springs, so I used two sets of the manual ones for safety. Took a long time, but the coil always seemed very secure in the compressors. Grease the threads and washers well, makes the job easier and safer.
Final installed shot:
Things I learned:
- Spraying down all bolts with penetrating fluid once per day for a week before made for easy removal. Just a regular 1/2" breaker bar was all I needed and I didn't break anything.
- Buy new tophat components for the coilovers. Salvaging your factory ones is time consuming and dangerous, and the parts may not be in the best shape depending on your vehicle history. Nisstec offers to prebuild the OME coils, that's not a bad way to go.
- Buy the camber bolts. I planned on installing mine, but I was so far behind on time I will just take them to the alignment shop and pay their labor if they need installed.
Overall it's still worth doing the work yourself to know that it was done right, learn more about your vehicle, and save money. I would just spend a bit more up front on new coil parts next time. Everything else was straight forward and the type of job that I could do again in 1/3 the time.