Suzuki Club UK

So I'm putting together my leaf springs after getting bits back from the painters,

I bought this polybush set from bits for vits


As you can see the kit only comes with crush tubes for the larger bushes, does that mean standard leaf spring polybushes don't require crush tubes?

As I'm running a calmini kit, it uses a different arrangement of bushes. I'm using the smaller bushes in the shackle but the crush tube from the large bushes don't fit.

Here is the shackle with the bushes fitted alone



And what happens when I try to fit the crush tube



So basically do I even need the crush tubes? Or does any one have a master plan on how to get the crush tube in without the bush pushing out?

I didnt, from a really bad memory , use the tube with the small bush. I just did as pic

So large bush with with sleeve goes in tower, small ones go in shackle.
I could be talking crap but Im sure that was how I did mine

Tube is only in the original chassis mount end.

The original SJ shackles have a stepped bolt in them to prevent over tightening.

So we have success,



I think the root cause of my problem was that the poly bushes weren't the right size for my calmini kit, which is fair enough, I could get the bushes into the shackle but the fit was tight. The second issue was that I'm using a polybush that isn't supposed to have a crush tube fitted.

To get them to fit I used the long threaded m12 bolt (with washers and a nut) to squash the bushes into the shackle I also had to cut a few mm off the back of each bush as when I fit the crush tube the polybush expands around it and pushes one bush out. I also had to modify the crush tube by cutting it in half and inserting them both at the same time, this kept the pressure squeezing the bushes inward so they stopped in fine

Success!

Nice job!