Our In-House Engineer’s personal Scion FR-S

While most of us are pretty much desk jockeys here at TEIN USA (just kidding!), some of our staff enjoy spending their free time at the local race track. Local to us southern Californians is something like a 1 hour drive on average.

One such racing enthusiast is our very own in-house engineer, Shuichiro (a.k.a.- “GQ”). He occasionally takes one of his daily drivers to the track. He’s currently driving his 2013 Scion FR-S. Prior to this, he had a well-prepared Honda S2000. However, there was one occassion where he tried to get all environmentally friendly and drive a Toyota Prius. Dunno what he was trying to do there. He was probably all like “I wanna be like Brad Pitt” or something. Don’t get me wrong, he’s still a true race enthusiast. That hybrid car stuff was just a phase we’re trying to forget about…

He was told to "look natural". This is his idea of "natural". So GQ.

He was told to “look natural”. This is his idea of “natural”. So GQ.

But yes, he’s an enthusiasts. Whenever he has the chance, he’ll prepare his car for track duty. Being that he works at TEIN, that means he has access to any one of our suspension kits.

We are actually making his car our guinea pig for damper development, for both new product and experimental damper valving. Since it is easier to do so with our 2-way adjustable setups, we have him run our Super Racing coilover. Not a bad hookup for making him our crash test dummy! I mean, test driver. In the name of science!!!

The current build sheet for his FR-S is as follows:

*Exterior
Front lip spoiler: Revolution
Side skirt: Downforce Evasive (exclusive model)
GT wing: Voltex Type1S
Duck bill: Five Axis
Fender Spoiler: TRD

*Interior
Seat: Recaro SP-G
Harness: TAKATA Race 4

*Footwork
Coilover: TEIN SRC (Ft9kg/Rr10kg)
Wheel: Advan GT 18×9.5 +40
Brakes: AP Racing front big brake kit w/ 6 piston calipers
Brake pads: Project Mu

*Drive train
LSD: ATS&Across

*Engine
Intake: Revolution
Throttle Body: Revolution
Exhaust manifold: Fujitsubo SuperEX
Front pipe: Berk
Cat back: Fujitsubo Authorize R Type S (w/ burnt tip)
Oil cooler: Greddy
ECU: Ecutek

A very simple build. Nothing too over-the-top, and definitely a good platform for us to continue damper development on. In fact, the FR-S/BRZ has been one of the best selling of new vehicle platforms for us in terms of suspension sales!

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So, if you see him at events, especially around Buttonwillow, don’t hesitate to say hi to him. Better yet, prepare a bunch of technical questions to ask him in case you run into him! He loves that kind of stuff. Apparently.

TEIN Has Two Manufacturing Plants?!

That is correct!

Earlier in 2014, we posted about the new TEIN China manufacturing plant, which construction of the plant was completed before the end of the year. This new plant will be focusing on production of our upcoming line of performance replacement dampers. YES, we will finally be working on replacement dampers designed to work with factory springs, as well as our S.TECH & HIGH TECH lowering spring kits! We’ll blog more on this product later.

However, this will not be the first manufacturing project for TEIN China. We’re going to be receiving our new STREET BASIS Z & STREET ADVANCE Z damper lines from the TEIN China plant.

If you had read our previous posts regarding the new “Z” line, you’ll notice that the other Z line of dampers, our FLEX Z coilovers, will be coming from TEIN Japan. Why is that?

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TEIN Japan’s Yokohama plant. This new facility was opened in January 2014.

It’s a little difficult to explain. But, in short, TEIN is still a very proud Japanese brand. In fact, many of TEIN’s domestic customer base prefer a Japanese manufactured product, especially more of the high-end kits we offer. So TEIN Japan will still continue to produce some of our higher end product lines, such as the upcoming FLEX Z & FLEX A, MONO SPORT, SUPER DRIFT, HG, SUPER RACING, GROUP N., and several other product lines.

That is not to say there is a lack of pride for the TEIN products coming from the TEIN China plant. In fact, we have invested a lot of money into this new plant in an effort to maintain the same TEIN quality our customers know and expect out of every product. Even machinery and equipment used in TEIN Japan will be the same in the TEIN China plant. A few of TEIN Japan’s engineers and managers will also be making the move to China, not only to train new staff, but to also control all operations. To us, this is a necessary step in controlling and maintaining TEIN quality.

Maybe this would have been a much easier undertaking if we just outsourced manufacturing of these more affordable coilover kits through some other Chinese or Taiwanese manufacturer. Sure, but that isn’t the TEIN way. We’re proud of our technology. Again, we’re not claiming to have invented dampers. We’re just proud to make suspension better through our own engineering and through our own technology.

Still though, why the new factory in China?

photo (Custom)

Our new TEIN China manufacturing plant!

A very good question. For several years now, we’ve faced stiff competition in the market place, especially with a lot of these somewhat engineered suspension kits selling for well under $1000. We’re not trying to defame any particular brand. So in their best interests, we’ll leave that information out. Sorry! We’re not here to bash on anyone!

It hasn’t been easy for us. For years, most of the feedback from our authorized dealers and wholesalers is how TEIN suspension is overpriced, and no matter how we dissected our manufacturing process in trying to reduce cost, it still didn’t gain the appeal for a broader range of customers. We were essentially becoming a boutique brand. We’re hoping that opening a new overseas facility helps to address this matter. Of course, this exploits a certain factor about manufacturing in China- affordable labor. However, we’re not in China to simply abuse this factor and gain in profitability. It is just a simple fact about the country and its economic structure, and this is how other manufacturers are able to price their products well below ours. This new affordability in manufacturing translates directly into a more affordable product for our customers.

It wasn’t an easy decision. In fact, it was an idea that we never knew would come to fruition. We didn’t simply decide to open up a new plant. We’re talking about a problem that hadn’t been addressed since late 2008, during the dreaded global financial crisis. Again, we could have simply outsourced manufacturing.  But, fortunately, we were able to hang on and maintain some profitability over the next few years in an uneasy industry. We had to outweigh every factor before we made this decision to grow. Now, it’s set in stone, and the TEIN China plant is just about fully operational.

Many of TEIN USA’s staff share the same regards as all other U.S. consumers when we hear “Made in China”. It clearly doesn’t have the appeal that “Made in Japan” does. Typically, we view Chinese manufactured goods as essentially NOT GOOD. That was just something most of us grew up hearing and reading about. It’s sad. Then again, think about how many other goods come from China… Why is it that China is commonly associated with terrible quality? I think this is something that TEIN plans to dispel. Being that we’re in control of all aspects of this manufacturing plant, we have the opportunity to change that “Made in China” label. We think that, naturally, Chinese manufacturing can improve.

All TEIN suspension products, whether made in China or made in Japan, will be covered with our manufacturer’s warranty. That won’t change. In fact, we’ll continue to offer after-sales service, such as replacement parts and dampers, as well as overhaul service, to all of our customers so that they can continue to use their TEIN suspension for years and years.

TEIN Replacement Single Dampers

As many of our customers are already aware, we’re able to sell single dampers as replacements. While not as cost-effective as rebuilding your dampers, it is a better time-saving method of getting your vehicle back on the road.  We know that some customers have heard from auto parts stores (probably non-authorized TEIN dealers) that TEIN will only sell complete kits. That isn’t true.

We’ve heard from customers wanting their dampers serviced by us, but concerned about the 2-2.5 week turnaround time. We know that for some customers, they only have one car to use. Being without a car for a 2.5 week minimum can cause havoc to their daily routine. This is why we are able to sell single dampers.

This same service will apply to the upcoming “Z” line of dampers, such as our STREET FLEX Z, STREET ADVANCE Z, & STREET BASIS Z coilover kits. Since they are all fully sealed, non-rebuildable units, it will be much easier to just replace the bare damper (pictured below, middle).

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Mind you, these are not merely damper inserts/cartridges like some other suspension manufacturers use. We mean the actual bare damper- no spring, no upper mount (FLEX Z), no lower bracket (FLEX Z). What’s the difference between an actual damper and a damper insert?

Our dampers are application-specific, meaning that each damper is made specifically for one vehicle model. Of course, there are some vehicles that share similar platforms where we can sell a single coilover kit part number (ex. 1999-2003 Acura TL = 1998-2002 Honda Accord).  In other words, we’re not simply using one design of shock absorber insert and placing them into damper bodies of various lengths just so we can say “Application-Specific”. Each coilover kit has carefully selected spring rates and dampers are valved to match (yes, we actually test each vehicle application before deciding spring rates and damper valving). That means that the internal components of the dampers, such as piston shaft, inner tube (for twin-tube dampers), and a few other components, have to be of a specific length for a given design. It is a timely and costly process, but it makes more sense to do it right. To be honest, we’re not too sure how well damper inserts work, especially if different vehicles require different damper valving and stroke length. It really doesn’t make a lot of sense.

damper and insert

You can see how a damper insert is put into an existing shell case.

Another problem with damper inserts/cartridges is their limited capacity. Because their overall dimensions are smaller than the shell case they’re being put into, that means less volume for damper oil.

oil capacity in a TEIN damper

oil capacity in a TEIN damper

oil in a damper insert/cartridge

oil in a damper insert/cartridge

 

For a performance damper, this limited oil capacity means susceptibility to damper fade and decreased damping force under extended use. That is why we make every coilover application to exacting dimensions for their intended vehicle. Unless it is an absolutely practical application, TEIN dampers will never use cartridges, ever!

Back on topic, this single damper replacement service is available for each and every one of our products, including the upcoming “Z” line, but will be much more affordable compared to the current rebuildable dampers.

For discontinued TEIN items or dampers we no longer have inventory of, we can remanufacture single dampers through TEIN Japan. The only problem is that customers may have to face extended downtime since the remanufactured dampers are made to order.

Our goal is to decrease a customer’s downtime on vehicle repairs. For us, this makes a lot of sense to be able to provide such service.

If you are having problems ordering a single replacement damper, please give us a call at 562-861-9161. We’re glad to assist you in getting your car back on the road!

Customized Suspension for Evo X Chase Vehicle!

This was a special project for us. Our good friend at Clockwork Media came by asking for suspension for his camera car that he uses for filming. You may actually be familiar with a lot of their work, as they do most of the videos for Scion Racing! So anything drift, rally, and anything in between that Scion is involved with, Clockwork Media takes care of a majority of it!

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Back to their need for suspension. As mentioned in the title, they use a Mitsubishi Evo X that is only modified with extra equipment to mount cameras and such onto the car. Their concern was that, with stock suspension and with a total of four passengers, the ride quality was still very harsh. This translated into very choppy looking video, as they played a clip of a chase run with the GReddy sponsored Scion Racing FR-S of Ken Gushi. On top of addressing the harsh ride concern, they needed a suspension kit that will maintain close to factory ride height (including the four passengers in the car).

This sounded like a pretty good challenge for us. For those of you familiar with our coilover products, you may already know that most of our kits are designed to lower vehicles, and most have a bit more aggressive spring rates and damper valving to enhance handling performance. So technically, we had nothing off-the-shelf to meet their needs.

However, we have the ability to do some customization in-house. Since all of our coilovers are rebuildable, we can customize internals and modify damper valving for specific spring rates.

Prior to deciding on what coilover package we could use, we did a quick corner balance on the vehicle to see how much more weight was added (excluding the passengers). Then, our engineer went to work looking up existing Evo X suspension kits we already offer. It turns out our STREET FLEX coilover was the best candidate for modification. The next problem- getting factory ride height and factoring the added weight of passengers and filming equipment. Typically, for such requests we have custom piston shafts made by TEIN Japan, then air freighted to us. Our engineer was able to find existing piston shaft designs to use, which saved them the hassle of having to design new ones altogether.

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Mind you, this doesn’t necessarily add more stroke. We’re still using an off-the-shelf coilover kit that has a set damper length. We just needed the extra length to use in conjunction with a taller and softer spring than what comes with the kit to be able to get close to factory ride height.

Once we got all the parts together, our engineer went to work on final spring rates and damper shim specs. Then we assembled the dampers. Overall, the dampers are MUCH LONGER!

Here’s our STREET FLEX kit as it comes out of the box:

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Here’s the front STREET FLEX compared to the newly modified one:

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And the rear STREET FLEX compared to the modified one:

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Compared to the stock suspension, our modified STREET FLEX dampers are very close in overall length

Fronts:

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Rears:

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Starting with the rears, it was as simple as unbolting the stock suspension, upper mounts and all, and swapping in our coilover

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There’s quite a bit to do to remove the front suspension, but at least putting in our STREET FLEX setup makes it a quick bolt-on affair.

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We certainly hope all of you installing our suspension are double-checking each bolt/nut, spring seat, etc. to make sure they’re torqued to specification. We may have the dampers preassembled and they may look ready to go right out of the packaging, but it is wise to check every component prior to attempting to drive on them. Follow torque specifications listed in the included installation manual with your coilover kit.

Our engineer is double-checking the torque on the hex bolts for the camber plate. These require relatively low torque (12-3 – – 13.74 ft-lbf).

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Seatlocks for locking lower brackets will vary depending on design (strut type= 101.2 ft-lbs, multi-link= 50.6 ft-lbs). For strut type lower brackets, we also include a conical washer between the bracket and seat lock. This must be tightened completely with no visible gap when it is torqued properly.

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When all was said and done, the car looked,,,,,,,, well, it looked stock. Kind of unusual for us since we expect a car to end up lowered (unless we’re installing an HG or Group N coilover kit, that’s a different story). Again, this is what our friend wants. They need to make it a more comfortable and less harsh of a ride to get those great pictures and videos while on the move!

Front ride height:

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Rear ride height:

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We certainly hope our friend likes the new suspension. Being that we can customize our coilovers, there are still endless possibilities in terms of different spring rates and damper valving, depending on their needs!

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clockwork evo