Ironman 4x4 foamcell struts (1 Viewer)

[Winged]

So I had these less then a year coilovers and while doing the LCA I found them both making contact. The spring and the body of the strut is contacting and making noise while I drive(I thought it was a busing). I contacted Ironman and talked to some in the warranty department. This is the resolution “
It does appear that the coil was not centered correctly on the coil over, and if we had built the coilover, we'd take responsibility for it.

Alas, your kit was sent to you unassembled, so the responsibility for the un-centered coil is the assembler's.

Sorry about that. Our hands are tied at this point.”

I included pictures so what do you guys think ?

 

[Winged]

Continued

 

[Winged]

Last one

 

[r2m]

Last one

View attachment 2988010

As I was looking at your photos, the assembly has to make the spring self-centering because they're in molded seats, centered in the top and bottom of the shock.
So scrolling through your photos, I'm guessing that the spring is bowed.
Well, low and behold! Your last photo confirmed my suspicions about that spring. That IS a factory defect. Send it to them and have them replace it.
Even if the top and bottom seats on the shock were canted a wee bit, the spring wouldn't stay bowed. In fact, there is probably enough energy in the spring that if the seats on the shock were a bit off, the spring would seat them correctly.

 

[aztoytec]

Is it upside down? (Does it matter?) The part numbers on the spring are.

 

[Winged]

Is it upside down? (Does it matter?) The part numbers on the spring are.

according to this video the flat part of the spring goes up and the pig tail is bottom. The part number did throw me off when assembling it.

 

[re_guderian]

Is the lower seat frozen to the adjustment rings? If it is, it seems that it would alter the clocking of the lower spring holding point, and tend to rotate it, which could then attempt to "unwind" the spring, resulting in bowing? I don't have adjustable lift springs, so maybe I'm talking out of my rear end, but it looks like both top and bottom of the psring are seated, the only question is whether those seats are in the correct orientation to each other, and when they were installed.

 

[re_guderian]

Is the lower seat frozen to the adjustment rings? If it is, it seems that it would alter the clocking of the lower spring holding point, and tend to rotate it, which could then attempt to "unwind" the spring, resulting in bowing? I don't have adjustable lift springs, so maybe I'm talking out of my rear end, but it looks like both top and bottom of the psring are seated, the only question is whether those seats are in the correct orientation to each other, and when they were installed.

I'm talking about this interface here. I assume the lower spring seat is NOT supposed to rotate as preload/lift is applied? What is the condition of your interface here?

 

[Winged]

These are the top and bottom rubber isolators. The picture of the coil over is at full Droop and the spring is under tension.