MC Hammered

We tried rotating the rear passenger side spring and it sure helped with how the spring looks when unweighted on the perch. It sits flush on the perch and doesn't look like it is going to peel off the perch like it did before.

Rotating the spring did lower the frequency of when the clunking noise happens but not get rid of it entirely. So we know it is the spring coil occasionally rubbing against the lower metal perch but don't know if rotating it any more would help or worsen the state I am in.

My tech says the metal spring on a metal perch is the issue. If a rubber lower seat spring was used I wouldn't get any noise but I would get more flex.

diagnosticator1

The only additional flex that can occur is concentric/in parallel with the reaction forces at each end of the spring. As that is the only direction of forces acting on the ends of the spring, any additional flex is added to the overall spring compliance, and does not introduce any other flexural motions in the suspension.
Said another way, you should use rubber spring seats regardless of the alleged additional flex, as any flex occuring won't effect the suspension motion.

MC Hammered

but I got the picture.

The lower rubber perch has some give vs. the metal perch that doesn't.

In any case I don't know why Stasis uses a new lower metal perch but retains the stock OEM upper rubber one.

We know the clunking noise is the lower spring coil contacting the lower metal spring seat.

diagnosticator1

in your Stasis equipped Audi. Using a rubber lower spring perch would not compromise the performance of the suspension due to the fact that the forces at the spring ends only act in the same directions as the reaction forces at the ends of the spring. And, as I tried to explain before, if the preload on the spring was not allowed to decrease to zero before maximum suspension extension, the issue would not occur in the first place.

EBG 18T [Eric]

i have the oem upper, the hyperco spring and the plastic washer on the lower metal adjuster. I thought i remembered seeing the plastic washer on your lower perches. did i miss something?

520

Note the black rubber-looking rings on both ends of the spring...
<img src="http://pictureposter.audiworld.com/37962/dsc03552.jpg">

It's 1/16" thick Shore 90A urethane. Buy a sheet and cut rings to fit your springs/perches. Noise may go away and they will last forever...mine held up through 1,000 miles of track time and my CO's are still quiet.

Your problem may be elsewhere though?

Merkin

shear and stretch of 90A is lower

where did you get the sheets? mcmaster carr?

MC Hammered

Everything that should be there is there so we are at a loss as to what to do next.

MC Hammered

I don't know how adding the urethane spacer would help.

I'd need to make something that goes between the spring and the lower seat to keep the spring from contacting the perch.

Merkin

energy suspension sells universal polyurethane seats