BDS Suspension Blog

View previous article: How we design new lift kits (Part 1)

Steering knuckles have arrived and so does a new truck. Phase one of the installation consists of taking lots of measurements (ride height, strut height, coil length, anything and everything we may ever need and then some more) as well as several thorough test drives. After the measuring is done, the tear down begins. All items that will be relocated are removed from the vehicle and a clean undercarriage is ready for modification.

At this point we take a step back and decide on a general plan that will meet our main objectives. First, we want this kit to install easily. The R&D department is constantly installing kits to make sure everything fits on new and old models. We do not use hammers to install our kits; it needs to fit and fit well. Next, it needs to look good on the truck. The recently released High Clearance designs give trucks and SUVs a tough clean look. Along with an aesthetically appealing design the kit has to function on and off road. We match the factory geometry to keep the on road performance. Off road performance is improved by strengthening and protecting the undercarriage and increasing ground clearance. The final key feature is the strength of our parts. We offer the best warranty in the business and stand behind our products for a reason, and if you somehow manage to break a BDS part… you deserve a new part.

We have a plan of attack set, and start by creating models in Solid Works (Our 3D CAD software) and virtually installing them on the frame. Measurements are double checked with the truck on the hoist and tolerance ranges are set. We are feeling lucky and cut out our first set of brackets on a CNC (computer numerical controlled) plasma table. Plates are formed in the press and welded up. The raw brackets are installed and revisions are created. If everything looks good, the brackets are clear coated and reinstalled. Once again the rest of the factory parts are installed on the truck with the exception of the coils on the strut (or torsion bar adjusters).

The first testing the kit undergoes is a complete range of motion test, this ensures that brake lines are long enough and there is adequate clearance between moving parts. Wheels and tires are installed with clearances once again noted. This is why the backspacing that we list is critical. An aftermarket wheel that is the recommended size will give the best possible clearance and allow for the largest tire size. The coils (or torsion bars) are reinstalled and the truck is off for its maiden voyage to the next hoist for an alignment. Alignment specifications are printed and filed along with any noted areas of interest for the next test installation.

Finally, it is time for a real test drive and a lot of miles to be driven…

With the King of the Hammers race just two weeks away our crew at Pacific Fabrication continues to prep the truck to make sure it’s race ready.  Some of you may recognize this rig from the 2009 Petersen’s Ultimate Adventure covered in a few issues of the mag and of course the video.  Even the boss, “Jen” is putting in some time getting the bead locks ready for the big day!

BDS Suspension has announced its  JEEPSPEED sponsorship of Chase Rather racing.  This is his 4th year racing in the JEEPSPEED series and was named Rookie of the Year. At age 16, Rather is the youngest driver to join the JEEPSPEED circuit, placing 1st at the Henderson 400.  We encourage you to watch and support Chase in his BDS Long Arm equipped Jeep XJ. You can find this season’s schedule and more information about the JEEPSPEED Desert Race Series at jeepspeed.com .

Here at BDS we have a dedicated R&D team that is continuously creating, installing, testing, and improving our products. How do we even begin to make these lift kits, where do we even start? The answer depends on what type of suspension system we are working on. In this article, we will focus on the most difficult and time consuming suspension lift kit to design: A replacement knuckle IFS lift.

A replacement knuckle is difficult and expensive to design. This is the most challenging part we make and will dictate every other feature of the lift kit. All of the steering and suspension angles need to match in order to keep the factory ride and stability control features. The casting needs to fit within a certain sized mold, has to have good material flow characteristics, and have enough material to machine off, but not too much material that creates a lot of waste. After a week of crunching the numbers and a couple calls to the foundry and machine shop we end up with the cast and machined models.

About 2 months have passed and a bunch of samples arrive. They are now off to get x-rayed for any possible defects. After x-ray the parts go to the painter for powdercoating and to the machine shop after that. 4-axis CNC machines cut all of the features and a CMM (computer measurement machine) checks all of the features to make sure they are in specification. The tolerances on certain features are extremely tight, about the thickness of a sheet of paper. Finally, two sets of machined knuckles arrive to the R and D department and now we can really get started…

We recently released the 6-inch 09-10 F-150 High Clearance 2WD suspension system. Thanks to our friend Doug McColloch for featuring it on the fourwheeler.com blog. Click here to read more about the F-150 6-inch HC system  http://blogs.fourwheeler.com/6629019/reviews/six-inches-for-two-driven-wheels/index.html