Bilsteins Broke - Time to Upgrade?

[Lucky_13]

This past weekend at the track, the stabilizer bracket on one of my Bilsteins gave up the ghost and slashed a tire on me (image attached)

Needless to say, not too happy with Bilstein at the moment. I've run koni yellows in the past (and have them on the front now) and think they ride terribly, but perform decently. However, I'm looking to upgrade.

So far, the setup that keeps coming back around is KW V3. I do 3-4 track days a month during the summer, but otherwise she is a daily in Michigan so the stainless bodies appeal to me. Anyone else have any recommends? I have a set of Vorshlag CC plates already.

 

[sheizasosay]

Yeah I don't know man. You are throwing me off with the whole "Koni's ride terribly" part. But I'm guessing that the roads where you live are bad. I happen to think they are *very good*. I actually have never seen this failure on a bilstein. Makes me wonder if their was a torque problem.

If money is an issue I would go with Ground Control. If money is not an issue I would go with MCS.

 

[Lucky_13]

Maybe, I kind of wish it was a torque problem...but that rust under the top weld makes me think it wasn't penetrating enough to begin with.

 

[BMR Tech]

Not to change the subject here.....but this has actually happened to my customers on several occasions. Once with Bilstein, and a few others with OEM and I think a Koni. Regardless, it's happened a few times.

What kinda front bar, and end links are you running?

I wonder if a modded sway bar saddle bracket would/could be used to re-enforce those brackets? I may look into it.

 

[Lucky_13]

Not to change the subject here.....but this has actually happened to my customers on several occasions. Once with Bilstein, and a few others with OEM and I think a Koni. Regardless, it's happened a few times.

What kinda front bar, and end links are you running?

I wonder if a modded sway bar saddle bracket would/could be used to re-enforce those brackets? I may look into it.

Hey Kelly,

No problem. It's a strano 35 mm bar, which puts a good deal of force through the stock endlinks. I actually emailed Sam and he told me that early Koni's suffered the same failures, which is why their bracket is now welded all the way across the shock.

The bracket slashed a tire on me on the back straight @ about 110 mph, thankfully was able to limp back to the pits and it wasn't much worse than a popped tire.

I've actually been really satisfied with the Bilsteins but don't want the situation to repeat itself. I got my kit from Jason at Vorshlag, and while he's been great at trying to help me out, Bilstein has been radio silence

 

[BMR Tech]

Yeah, like I said - I have definitely had customers bring these exact occurrences to my attention.

We recently released our front end-links, and are about to release our 38mm front bar.....which has a VERY aggressive "stiffest" position. I have been having concerns about this, more so now since we have a bar that has a 1000lb/in+ setting.

I know you may not want to tackle the Bilsteins again....but here is what I was referring to in my previous post, to give you an idea. I think this would be an excellent mod for people running serious rate bars, with rigid links.



I hope Bilstein has good news for you sir. Good luck.

 

[Lucky_13]

Ah, now that's something I'd be interested in, if only for peace of mind. These cars love some serious rate up front, I'm just happy me and the car stayed in one piece!

 

[BMR Tech]

I am happy that, that is the case as well!

Not sure if we will make this piece....BUT, I highly recommend you possibly checking into making the mod.

 

[Lucky_13]

I might give it a go, I've got a bunch of leftover saddles from various bars I was experimenting with. The welds on KW's V3 setup seem beefy, though...so maybe I won't have to do all that much.

 

[BMR Tech]

I agree. The KW's use dual mounting pieces, with much more welded area.

If you can make something work, that you have laying around, though - I would.

Even with more welding, that is a very large amount of load on those tiny brackets.

Keep us updated with what Bilstein has to say, if anything, if you would.

Good luck sir.

 

[jayel579]

It's a strano 35 mm bar, which puts a good deal of force through the stock endlinks.

Where are you running Sam's bar at? I have the same bars in my car and have them both at full soft, a little too much bar if you have heavier linear rate springs (575#F,350#R) IMO.

 

[Lucky_13]

I was on P springs, so ~200 ish I'm guessing and on the middle setting of Sam's bar. I'll probably tone the bar down if I get the KWs, because from my understanding they are around 400 front.

 

[jayel579]

I'll probably tone the bar down if I get the KWs, because from my understanding they are around 400 front.

I am on KW Clubsports to give you an idea on what spring rates come on them.

 

[skwerl]

Lucky (and Kelly),
Would adding a flat steel reinforcing plate across the two bolt holes on the strut help? I'm thinking that by bolting a steel plate to the strut and the end link bolt passing through the plate to bolt to the strut would distribute the load of the sway bar over twice as much area on the strut. This would reduce the tendency for one end of the mounting tab to shear off as shown in Lucky's image in the first post.

 

[BMR Tech]

^ It would help keep the tab from separating.....but may actually increase the load to the welds - possibly increasing the chance of shearing it off the strut body.

The goal would be to re-enforce the bracket to the strut body.

 

[BMR Tech]

Brian, I do think that your idea on a bracket like the KW (two individual welded tabs) would be an excellent, cheap and easy modification.

Just not sure about the thinner, single piece designs with minimal welding.

 

[modernbeat]

Mike sent me photos of the Bilstein. Looked like one of the four welds, one of the two on that side, was not a good weld. Once it started flexing under the force of the swaybar, it was all over. Bilstein has verbally agreed with me it's a warranty claim. There are some hoops to jump through to complete the claim, but I expect a replacement soon. This is the first Bilstein warranty claim I've ever had to do.

 

[5.0 Probie]

Mike sent me photos of the Bilstein. Looked like one of the four welds, one of the two on that side, was not a good weld. Once it started flexing under the force of the swaybar, it was all over. Bilstein has verbally agreed with me it's a warranty claim. There are some hoops to jump through to complete the claim, but I expect a replacement soon. This is the first Bilstein warranty claim I've ever had to do.

Outstanding service!

This thread made me nervous until Jason posted! lol