Front Air Spring Installation

Our custom fabbed style chassis and Heidt's front end are designed for coil over shocks only. Installing ShockWave air springs & shocks has to be a custom installation job if we really want them as an option-and we do! Coil over shocks are approximately 3" diameter and take up much less room than a ShockWave air spring/shock combo (which are approximately 6" round).

As you can see in the 1st photo showing the installed front air spring/shock, a serious notch needs to be installed in the frame rail. At the vehicle ride height, the ShockWave will run between 12 1/4" -12 1/2" center to center (of the mounting eyes). After mocking up the body and establishing the vehicle ride height, we discovered that the upper mount (for coil over installations) was about 3/4" too short and needed to be moved inward toward the center of the chassis to get the air bag away from the top of the spindle. We used a piece of all thread, paper & cardboard rings, and nuts & washers to simulate the air spring, which in turn enabled us to design the new upper shock mounts. At the end of the all thread, we installed a pair of machined aluminum blocks which simulated the eyes on both ends of the ShockWaves. After designing and having a new set of upper mounts laser cut, we installed them as follows: 1) We set the lower A-Arm at a predetermined height (we established that measurement when we set the body on earlier), 2) We bolted the all thread and aluminum blocks to the lower A-Arm & new upper mounts. The aluminum blocks were set at 12 3/8" center to center (which is the manufacturers recommended ride height c/c), 3) We tacked the upper mounts only as we will do the final weld later after determining that everything is just right.

Pocket Fabrication

Once the upper shock mounts were tacked in place, we used a cardboard ring to mark and cut our pocket cutout (using a plasma cutter-a torch would work also). We know this sounds and looks easy, but remember, we are working on an angle which creates an unusual angled cutout. Try doing that with out the aid of a jig and template combination. Rather than attempt a fabbed or sheet metal type of notch, we decided to turn up a custom profile pocket out of billet 7" diameter mild steel (natural since we are crazy overkill machinists). The design follows the contour of the bag shock aluminum top, and allows for adequate clearance regardless of which position the bag is in (ride height or collapsed). After we finished turning up the piece, we cut it in half on the band saw (how nice, one turned up piece gives us both sides-man are we smart or what!).

Pocket Fitting

We further enhanced our all thread jigging rod by making up a pair of upper and lower pocket locating pieces. These not only hold the pocket the correct distance from the center and enable us to establish the up and down measurement, they also hold the pocket for tacking. Once the pocket was set into place, we were able to mark it for milling the angled sides (remember, the pocket is on an angle). We set up a big vise on the milling machine table (at the marked angle) and milled the sides of the pocket. This will give us a seamless blended look after welding and finish grinding.

Front Air Spring Mock Up

Ah yes, a final mock up. The results not only give us the option of running air suspension (ShockWaves), but also look great too! The only thing left is the finish weld & grinding, and the plumbing to the top of the shock (air lines). We will utilize the all thread and aluminum blocks as a solid support strut for most of the initial construction since the air spring collapses without pressure.