Found a new bump stop option.

[FunctionSpec]

Ok I think I found what caused the Bilsteins to prematurely break. After closer observation, I noticed the Bilsteins do not fully compress and that there's a 1.5 inch gap between the top of the strut body and bottom of the strut bearing. So a bumpstop that is 2.75in in length only has about 1.25in of up-travel before it bottoms out on the shock. If we estimate that the bumpstop compresses about 50% of it's length during a hard bump, that would be 1.38in of compression, which slightly goes past the amount of cushion these bumpstops provide. So really what that means, the bumpstops aren't protecting the shocks at a certain point and the shocks themselves are bottoming out during hard bumps.

I think the Bilsteins were designed to be used with the OEM bumpstops. There's a plastic spacer on the OEM bumpstop that limits up-travel by about 0.75 inch. Full length of the OEM is about 3.5in. The plastic spacer provides some insurance to protect the shock but knowing that the OEM bumpstops will crap out in a year or two has me worried. A crumbling bump stop doesn't provide much protection.

Quite the dilemma here. I need a bumpstop that's at max 3.5 inches long, any longer than that and the car is pretty much riding on the bumpstops. A bumpstop that isn't too "squishy" and is firm without compressing too much. The Febi bumpstops I have compresses quite easily the first 0.5 inch and then stiffens up. But I do have some time to figure out since these Bilsteins are on backorder for 5-7 weeks

[Jason@SportsCar]

Originally Posted by FunctionSpec

Ok I think I found what caused the Bilsteins to prematurely break. After closer observation, I noticed the Bilsteins do not fully compress and that there's a 1.5 inch gap between the top of the strut body and bottom of the strut bearing. So a bumpstop that is 2.75in in length only has about 1.25in of up-travel before it bottoms out on the shock. If we estimate that the bumpstop compresses about 50% of it's length during a hard bump, that would be 1.38in of compression, which slightly goes past the amount of cushion these bumpstops provide. So really what that means, the bumpstops aren't protecting the shocks at a certain point and the shocks themselves are bottoming out during hard bumps.

I think the Bilsteins were designed to be used with the OEM bumpstops. There's a plastic spacer on the OEM bumpstop that limits up-travel by about 0.75 inch. Full length of the OEM is about 3.5in. The plastic spacer provides some insurance to protect the shock but knowing that the OEM bumpstops will crap out in a year or two has me worried. A crumbling bump stop doesn't provide much protection.

Quite the dilemma here. I need a bumpstop that's at max 3.5 inches long, any longer than that and the car is pretty much riding on the bumpstops. A bumpstop that isn't too "squishy" and is firm without compressing too much. The Febi bumpstops I have compresses quite easily the first 0.5 inch and then stiffens up. But I do have some time to figure out since these Bilsteins are on backorder for 5-7 weeks

If you like the new stops you have just make a spacer so they engage early enough to prevent the strut from bottoming. With a cheap delrin cutting board and a hole saw you should be able to make a nice spacer.

[ern-diz]

Originally Posted by Jason@SportsCar

If you like the new stops you have just make a spacer so they engage early enough to prevent the strut from bottoming. With a cheap delrin cutting board and a hole saw you should be able to make a nice spacer.

Do you also suspect that's what's happening? I'm about to install B8's and based on this thread, am trying to decide if I should run the shorter stops or get new OEM size.

My Tein springs instructed to cut the OEM stops to a specific length. If the B8's are designed to replace OEM from a ride height perspective, then they should require shorter stops in a lowered application...

[Jason@SportsCar]

Originally Posted by ern-diz

Do you also suspect that's what's happening? I'm about to install B8's and based on this thread, am trying to decide if I should run the shorter stops or get new OEM size.

My Tein springs instructed to cut the OEM stops to a specific length. If the B8's are designed to replace OEM from a ride height perspective, then they should require shorter stops in a lowered application...

That replacement shock clearly (looking at your pic) is bottoming and destroying itself. Most of the Bilsteins I have used included a bump stop, which was slightly softer than a hockey puck. I would say this is a case of a replacement shock that "fits" but was not engineered specifically for that application.

Even if Bilstein went to trouble of building a Yaris specific strut it would not have been built around your Tein springs - and you can assume by the Tein instructions they expect you to be using OE struts.

I would use the OE stop or put a spacer in that lets the aftermarket bump stop do its job. You could still trim it a little, but it needs to protect the strut.

[ern-diz]

Originally Posted by Jason@SportsCar

That replacement shock clearly (looking at your pic) is bottoming and destroying itself. Most of the Bilsteins I have used included a bump stop, which was slightly softer than a hockey puck. I would say this is a case of a replacement shock that "fits" but was not engineered specifically for that application.

Even if Bilstein went to trouble of building a Yaris specific strut it would not have been built around your Tein springs - and you can assume by the Tein instructions they expect you to be using OE struts.

I would use the OE stop or put a spacer in that lets the aftermarket bump stop do its job. You could still trim it a little, but it needs to protect the strut.

Gotcha, thanks for the input.

To clarify, I'm not the OP and that wasn't my picture. I'm just in a similar position where I'm running Tein S. Tech springs and am about to replace the OEM shocks/struts with the B8's. I'm happy to buy the FEBI stops, new OEM stops and use at full size or new OEM stops and cut. Just trying to find the ideal setup.

Since my B8 struts will be new in-box, I'm going to wait to see if a stop is included. If so, what size and go from there.

[ElMagnifico]

Originally Posted by ern-diz

Gotcha, thanks for the input.

To clarify, I'm not the OP and that wasn't my picture. I'm just in a similar position where I'm running Tein S. Tech springs and am about to replace the OEM shocks/struts with the B8's. I'm happy to buy the FEBI stops, new OEM stops and use at full size or new OEM stops and cut. Just trying to find the ideal setup.

Since my B8 struts will be new in-box, I'm going to wait to see if a stop is included. If so, what size and go from there.

Any updates?

[myfirstyota]

Originally Posted by ern-diz

Since my B8 struts will be new in-box, I'm going to wait to see if a stop is included. If so, what size and go from there.

Mine were new in-box, all they came with were the nuts for the top of the shocks. No bumpstop included

[ern-diz]

Originally Posted by ElMagnifico

Any updates?

Thanks for checking in. Between work and life, I haven't looked at Jegs or one of the other usual suspects for better than OEM bump stops and top mounts, so I haven't installed the B8's yet.

Originally Posted by myfirstyota

Mine were new in-box, all they came with were the nuts for the top of the shocks. No bumpstop included

Worst case, I know I can go with a fresh set of OEM stops and mounts and just cut the stops like I did when I installed the springs.