[zzyzx]

Here's the press release. I intend to maintain a full FAQ for this product on my website, so everybody's questions are addressed.

I'm still in the process of building the first "poster child", so pictures aren't ready yet.

Link:

"EM Sport" Coilovers | Zzyzx Motorsports

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Zzyzx Motorsports is proud to announce a newly developed set of coilovers, targeted at a much lower price point than our current all-aluminum Competition coilovers. To date, the market has lacked a proven set of affordable coilovers based on the tried-and-true KONI 8611/8610 series dampers. That time has come: the "EM Sport" coilovers have arrived.
Our expertise in the design and manufacturing of coilovers for the Mitsubishi Evolution and Subaru Impreza (WRX, STI, RS) using KONI dampers has enabled many of our customers to trophy at SCCA National autocross events, where our products have undergone extreme conditions and been proven to provide a winning combination for our die-hard motorsports competitors.
This time, we turned our efforts to producing a set of coilovers for you, the enthusiast. However, the flexibility in our design addresses the needs of not just a street-oriented enthusiast looking for a sporty ride, but ultimately the same level of performance demonstrated by our Competition coilovers. Unlike any other offering currently available, these coilovers can be upgraded and specifically configured to suit your needs by you when you first purchase them and when you later decide to upgrade them.
As your interests and experience evolve from street-oriented performance to a serious Time Attack or autocross dedicated ride, these coilovers can be user upgraded to address your performance goals. What does this mean? You save money by not having to buy an entirely new set of coilovers once you’ve surpassed your current sets limits. You save time not having to re-install your suspension and, most importantly, you save setup time on the track.


Features


• User configurable, user upgradeable. You can start with a set of single adjustable KONI dampers and upgrade as needed to double adjustable. No need to go out and buy an entirely new set of coilovers. Included in the upgrade kits from single adjustable to double adjustable are the built-in dial bump adjusters.


• Strut bodies constructed out of 4130 Chromoly steel, stress relieved and heat treated for superior structural rigidity and toughness. Nobody offers a strut as tough, durable and stiff as these. In addition, the strut bodies are also cadmium plated and then powder coated (or painted) for unsurpassed corrosion resistance.


• Single height adjustable via a threaded billet aluminum lower spring perch with a coarse ACME thread pitch and nylon tipped set screw, make ride height adjustments both quick and easy.


• Billet aluminum tophats include a built-in thrust bearing assembly to eliminate spring noise and stiction during steering inputs. There’s nothing more annoying than a noisy set of coilovers and addressing small details such as these are what results in a silent set of coilovers.


• Large dial rebound adjusters (at the top of the damper) and built in dial bump adjusters (if double adjustable, at the bottom of the strut). This ensures you can accurately and quickly change your settings when needed, and not have to run around looking for that tool you lost. The detents – “clicks” - on the bump adjusters are so easily felt by touch, you don’t even have to see under the car to set them – just reach under and count the clicks. And unlike many coilovers, there’s no guessing as to what the min and max settings are – they have positive stops.


• Your choice of spring rates. Thanks to the wide adjustment range of these KONI dampers, they support a wide range of spring rates. Simply put, they'll handle whatever spring rates you require in your application and we know this from first-hand experience in competition. So, if you’re after a smooth ride with softer spring rates, these coilovers will deliver. If you want to go stiff with minimal body roll, got for it. Due to the highly digressive valving, the ride will not be punishing or jarring, as is often the case with most Asian-manufactured coilovers.


• Wide range of camber adjustability using a unique eccentric bolt design. We've developed an eccentric bolt design that offers an unmatched range of camber adjustment – both front and rear - that is positive locking. Based on feedback from our competition coilovers, we felt it a high priority to have a positive locking camber adjustment mechanism, so we did just that. Depending on your goals, you could easily forego camber plates and simply use the eccentric bolts to set your camber.


• Unparalleled rear strut/tire clearance (Subaru only). Rear flange ears are extended to provide additional strut/tire clearance not offered on other coilovers. We’ve found from our Competition coilovers that this has been a welcome feature and have decided to offer in this feature in this design, also. This allows you to run a higher offset wheel with a wider tire to clear the fender lip without rubbing on the strut. Particularly critical on a WRX wagon.


• Your choice of springs (basic, Hypercoil, Swift). Whether you opt for Hypercoils due to their guaranteed precision and accuracy or Swift due to their smaller wire diameter and lighter weight, the decision is yours.

Applications
Subaru Impreza (all)
Subaru Forester
Subaru WRX STI (including ‘05+)
Subaru WRX (including ‘08+)
Mitsubishi Evo VIII & IX (all, USDM)
Mitsubishi Lancer (‘08+ - in development)
Mitsubishi Evo X (in development)

Pricing
Pricing is subject to change as we’re still sorting out final production costs, but have provided our best estimates below and intend to do our best to meet these projected pricing levels.
Pricing includes all components with the “basic” springs, excluding camber plates.
Stage 1 - Single adjustable Front & Rear: $1850.00
Stage 1.5 - Double adjustable Front & single adjustable Rear: $2050.00
Stage 2 - Double Front / Double Rear: $2250.00

What’s next?

We’re taking orders for our first production run, with an expected completion date of late January to early February 2008. If you want to lock in a set and get in on the first run for a guaranteed price of $100 below the prices outlined above, contact us!

[T3h_Clap]

this is an Awesome Idea.

if the quality matches your current products you'll have no problem with these bad boys.

any updates on your camber/caster plates?

[lovesmysuby]

Good job getting the word out here.

[stretch]

I'm happy to see these hitting the market since I'm a fan of Koni. What are you guys using for the valving on the SA Koni's- just off the shelf valving, or custom stuff?

These are obviously going to go head-to-head against Ground Control's stuff, but it sounds like you guys may win on features. I know it's petty, but I like that you're including larger diameter adjusters with detents in the adjustment unlike every Koni I've ever used! I'd also like to see your thrust bearing in the tophat; others have had that solution used in the camber plate tophat but never one designed for the stock tops.

Could the extended ears on the rear strut cause more seal wear in the strut due to higher lateral forces? I've had that discussion with another manufacturer who was considering the same, but ultimately were too worried about this. That said I'm sure 10mm or so wouldn't be too big of a deal.

I don't know if you've seen the critical damping analysis that I and 4banger have done for other products, but I'd love to do the same for your struts.

[zzyzx]

Originally Posted by stretch

I'm happy to see these hitting the market since I'm a fan of Koni. What are you guys using for the valving on the SA Koni's- just off the shelf valving, or custom stuff?

Yes, off the shelf. As wide a range of spring as we've run over the years, I haven seen a need to change the valving. Though that said, I will be offering more than just one type of KONI for this coilover product.

Originally Posted by stretch

These are obviously going to go head-to-head against Ground Control's stuff, but it sounds like you guys may win on features.

Rest assured, we've got the "features" covered.

Originally Posted by stretch

I know it's petty, but I like that you're including larger diameter adjusters with detents in the adjustment unlike every Koni I've ever used!

Just to be clear - Yes adjusters are included. It's my philosophy that you should be able to change your setup in grid, so I pay attention to the little details like this. However, rebound is still a continuous ~= 2.5 turns for adjustment. On a double adj. KONI, bump has a detent mechanism with 12 detents. The large dial adjuster magnifies this, so it transmits a very distinct tactile "click" are you don't need to see the adjuster to set it.

Originally Posted by stretch

I'd also like to see your thrust bearing in the tophat; others have had that solution used in the camber plate tophat but never one designed for the stock tops.

I've had this feature in my coilovers for years and it works well. You don't have any disgruntling spring popping noises when turning the steering wheel. I really don't like suspension noises, and these will be silent.

Originally Posted by stretch

Could the extended ears on the rear strut cause more seal wear in the strut due to higher lateral forces? I've had that discussion with another manufacturer who was considering the same, but ultimately were too worried about this. That said I'm sure 10mm or so wouldn't be too big of a deal.

That's a good question and I can definitively answer "no" to that question. I've had coilovers on dual-purpose cars that have been in service for years with no signs of trouble from the extended ears. Shock life of the KONIs have been excellent and is why I'm confident to offer them in more street-oriented coilovers.

Originally Posted by stretch

I don't know if you've seen the critical damping analysis that I and 4banger have done for other products, but I'd love to do the same for your struts.

I have and it's excellent work. Once I get all the relevant shock dyno data together and organized, I'd be more than willing to work with you on this and add the analyses to my website as part of the product data.

[Splash]

so, do the rear adjusters have extensions that allow adjustment with the rear seat in place?

[zzyzx]

Originally Posted by Splash

so, do the rear adjusters have extensions that allow adjustment with the rear seat in place?

They will if that's what customers want. I already need to do this for the rear on an Evo, anyways...

(BTW, I responded to your PM...)

[Splash]

Hmm... Might want to send that again.. I don't have any new PM's...

Anyway, on the extensions, unless all the EM Sport customers run SM or a road course class permitting rear seat removal, I'd bet it's pretty high on the list for anything non-inverted..... <grin>

[BigSky]

first I think you've done a good job of gauging the market

ballpark when these would be available?

basically these would differ from your current setup in steel vs aluminum for the strut bodies, single height adj vs double- same insert(s)? any other differences?

are you going to retain the oe eccentirc bolt and build eccentric spacers ala DMS? I for one would prefer using the beefy oe eccentirc bolt- not a 12mm one

[300hp owen]

awesome product idea and pricing, very cool.
but,
what are we to do for camber plates? and how much $$$ for them?

[zzyzx]

Originally Posted by Splash

Hmm... Might want to send that again.. I don't have any new PM's...

That's odd... and here I was wondering why you didn't get back to me. <sigh> I'll try again.

Originally Posted by Splash

Anyway, on the extensions, unless all the EM Sport customers run SM or a road course class permitting rear seat removal, I'd bet it's pretty high on the list for anything non-inverted..... <grin>

Agreed.

But... just for an FYI. There's a trick - if you unbolt your rear seat, then bolt it back it so it's only attached at the center (leaving the two corners off the hooks), you can readily pull back the seat enough to get your hand in there.

[zzyzx]

Originally Posted by BigSky

ballpark when these would be available?

Late Jan/early Feb is you get in on the first run. After that, it'll depend on demand.

Originally Posted by BigSky

basically these would differ from your current setup in steel vs aluminum for the strut bodies, single height adj vs double- same insert(s)? any other differences?

Those are two the largest differences right there.

Originally Posted by BigSky

are you going to retain the oe eccentirc bolt and build eccentric spacers ala DMS? I for one would prefer using the beefy oe eccentirc bolt- not a 12mm one

No, I won't be using the OE bolt. As with the Competition coilovers, I use a hardened 14mm bolt. The bolt itself will have a proprietary cam lob on it (at the head) that will enable the camber adjustment.

[zzyzx]

Originally Posted by 300hp owen

awesome product idea and pricing, very cool.
but,
what are we to do for camber plates? and how much $$$ for them?

I've finished a design, but no pricing yet. These coilovers will, however, work with a wide range of camber plates.

[BigSky]

Originally Posted by zzyzx

No, I won't be using the OE bolt. As with the Competition coilovers, I use a hardened 14mm bolt. The bolt itself will have a proprietary cam lob on it (at the head) that will enable the camber adjustment.

I guess I never saw your design for the bolt- very glad it's 14mm, not 12mm

[zzyzx]

Originally Posted by stretch

I'd also like to see your thrust bearing in the tophat; others have had that solution used in the camber plate tophat but never one designed for the stock tops.

Here's a freshly machined pair demonstrating how the thrust bearing is situated in the upper spring perch:



The races are hardened steel, and the thick one sits at the top, and the thin one in the pocket. This arrangement allows the tophat to rotate with the spring as the strut is turned by steering inputs and as a consequence avoids all the spring noise and binding. Should you need to re-grease the bearing or replace it, you'll need a simple snap ring tool, and you can take it right out for service.