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I tried to just let this go, but I couldn't.
I understand that you spaced the springs on some vehicles without apparent failure, but I assure you that by doing so you have decreased the life of the spring. I furhter assure you that most springs do not have much if any travel headroom before coil contact occurs or fatigue life is reduced.
Just because things seem to work does not mean they will work for any period of time, or in severe events when you may need them most. It also does not mean they are safe.
This may be acceptable for yourself. However, a broken spring could easily cause a very unsafe failure mode. For your own protection in these litigious times I would advise against this practice.
If you must have a low cost option I would space the spring and jounce bumper equally. (Equally if on a strut, proportionally if they are operating at different linkage ratios) It is the safest option that can be done very cheaply.
If you did that you may be able to show that due care was taken to prevent failure. (That is debatable, but it would show some care) If you don't do that you have made a tradeoff that reduces safety for the sake of increasing ride quality for your customer. Was your customer made aware of the tradeoff and still willing to make it?
As far as the comment about engineers that don't design in any options, I think that does not apply to this situation.
The owner _opted_ to buy an Aero. They could have easily purchased a base or V6 model that were not lowered. They could even purchase an Aero and have the _option_ of swaping appropriate suspension components. (probably springs and jounce bumpers, but perhaps dampers as well) They still have the _option_ of spacing the spring and the jounce bumper. (Which I do not endorse, but it is much safer than not spacing the bumper)
They do not have the _option_ of safely increasing free travel and ride travel without changing any components. This is not the engineer's fault, but physics and strength of materials.
-Joe
posted by 198.208....
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