Do-it-yourself air suspension. PP VAZ. Making air bags at home. Problems and solutions How to make pneumatic racks with your own hands

The air suspension allows you to adjust the ground clearance semi-automatically or completely without the use of physical effort. We are talking about replacing springs, springs and torsion bars with air springs, in which compressed air injected from the system acts as an elastic element. Despite all the advantages of this element, do-it-yourself air suspension can only be created if you have basic auto repair skills. The process is fraught with certain difficulties and a beginner obviously cannot cope with this.

Air suspension device

The design of each air suspension is represented by a receiver, a control unit, an air distribution system and a compressor. To improve driver comfort, suspensions can be either automatic or manual.

Automatic air suspension involves an independent selection of the ride height by electronics, taking into account factors such as acceleration, speed, slope. The benchmark in this case is aimed at high aerodynamic performance. The center of gravity is lowered, so the controllability of the machine is significantly increased.
Manual control requires the driver's initiative when choosing the clearance height relative to the road. Manual adjustment is also possible in relation to the stiffness of the suspension, if its design requires the presence of pneumatic shock absorbers.

Modifications

There are three modifications of air suspensions:

Single-circuit options are designed to be installed on one axle and provide the same pressure in both pillows on it, since the compressor and cylinders are located on the same circuit.
Double-circuit modifications are also installed on one axle, but in fact these are two single-circuit suspensions, thanks to which it is possible to adjust the height of the front and rear of the car relative to each other. The main disadvantage is the roll of the car, since there is a pressure difference between the two wheels that go along the outer radius.
Four-circuit options are considered the best, since four separate valves for each wheel, pressure sensors and a microcomputer are used for control. Therefore, the problem with the roll in this case is excluded, since the pillow steadily holds the necessary pressure.

Advantages and disadvantages of air suspension

Due to the positive properties of the air suspension, there is a tendency to install it both on trailers and trucks, as well as on cars. The advantages of tuning a car with air suspension are represented by the following features:

Ride height control. This improves handling in all road conditions. In this case, the springs do not need to be changed to softer and longer ones or short and harder ones (read also about).
When heavily loaded, sag can be avoided, as a constant ride quality can be achieved by adjusting the height and stiffness.
Handling is greatly improved, and the air suspension compensates for the difference between hard and soft springs by adjusting the pressure.
When driving on rough roads, body vibrations are smoothed out.
It is possible to install air suspension on any car.

The advantages are significant and there are many of them, however, it is worth knowing about the disadvantages:

Poor resistance to road chemicals and frost, which significantly reduce the life of the suspension.
The level of maintainability tends to zero, so the failure of one of the elements requires a complete replacement of the suspension.
The cost compared to traditional shock absorbers is much higher.

Air suspension assembly

Since a do-it-yourself pneumatic device is only a subspecies, installation is already possible on an existing car suspension. The essence of the installation is to replace the elastic elements with pneumatic cylinders, therefore, such a modernization scheme can be performed on any machine. It remains to learn how to make an air suspension with your own hands and how to install it.

Necessary tools, materials and equipment

The equipment in this case is standard and each driver has it if he periodically encounters the need for repairs:

sealant;
hammer;
metal brush;
Bulgarian.

Do-it-yourself air suspension consists of the following components:

a set of racks, even if the currently installed ones are reliable;
receiver (you can make it for the air suspension with your own hands and not buy it);
air suspension cushions;
compressor;
several different fittings and PVC pipes with a diameter of 6 and 8 mm;
electromagnetic valves in the amount of two pairs;
any oil and moisture separator will do;
manometer;
Control block.

Front suspension assembly

It is worth considering separately the technology for installing the rear and front suspension, since in the case of the latter, the scheme is more complex.

Knock the cap off the rack and clean the paint layer with an angle grinder.
Press the adapter onto the post and add spacer rings under it to increase the softness.
Select small diameter fittings or tubing and bring them to the air inlets in the adapter.
Install the air bag on the rack. The height of the bump stop should be calculated in advance, otherwise the spring may fail after the first strong blow on the road.
Use sealant and a copper press washer to seal the connection.
Fix the thrust bearing to the strut so that the rod does not rotate inside the shock absorber when the steering wheel is turned.
Connect the air tube to the pillow socket.
Now you can install the finished structure.

The step-by-step procedure for assembling the rear suspension is as follows:

Trim the spring cup a bit and remove the paint coating.
To the end of the rack rod, it is necessary to cut the thread for the pneumatics.
For the purpose of sealing, install the press washer and then put the air bag on the rod.
To achieve a special smoothness of movement, you can not install a bump stop, which will give a strong lowering of the rear of the car.
Press in the air spring to the end of the shock absorber.
Perform air supply.

Installation of air suspension on a car

Before installing the air suspension with your own hands, remove the racks from the car. Beginner skills in this case will be enough - just raise the car with a jack and follow the step-by-step process.

Use the existing rack mounting holes or make new ones as needed.
Remove the rubber bands and stretch the tubes to ensure air supply, then they must be fixed in relation to the body with clamps.
Fix the receiver on a special bracket near the gas tank.
Remove the tubes from the pillows along the steering rods and bring them into the engine compartment. Make the wiring in two directions - to the receiver valve and the discharge valve.
Connect the pneumatics to the toggle switches of the control unit.

Health check

Be sure to check the functionality of the system. After pressurizing up to 8 atmospheres, check for leaks in the system by ear, hissing should be absent. Next, set the pressure in the system to 6 atmospheres for the rear suspensions and up to 8 for the front. Do not rush when you pump air, otherwise there is a possibility of pumping the system by the compressor. At the final stage, adjust the wheel alignment.

Suspension control

The control unit with 8 buttons is responsible for controlling the air suspension. Each button is responsible for a specific rack or shock absorbers in the complex. To receive data from each airbag, be sure to install the controller in the passenger compartment of the car. Focusing on the road situation, you can reduce or increase the air pressure in the pillow to reduce or, respectively, increase the clearance.

In passenger cars, the suspension provides more comfort for the driver and passengers, hiding the bumps in the roads and keeping the car from loosening. Trucks are tuned with a new suspension to reduce the cost of their maintenance and repair.

If there is a desire, each car owner is able to tune domestic cars on their own. Even a do-it-yourself air suspension on a Gazelle can be mounted with the right equipment and the necessary materials.

In addition to the native suspension, many owners of GAZelle minibuses or its various modifications prefer to install an additional pneumatic system. After installation, cars receive significant advantages:

the driver in the process of driving is able to change the clearance and the degree of suspension stiffness;
reducing the level of risk during exceeding the carrying capacity of the vehicle;
increased comfort when driving on rough roads;
output on "native" suspension parts is reduced due to the redistribution of loads;
release of the load from the springs and mating hardware parts;
providing greater stability, especially with an adjustable air supply system.

Before you make an air suspension with your own hands, you need to know that all modernization pays off due to the benefits received. The approximate period at which investments will be effective is 30-40 thousand kilometers.

One of the negative aspects is the need for initial high financial investments. It also requires a sufficiently high qualification of the performers involved in the installation of the system. It is desirable that the team has a specialist with experience in working with pneumatics.

The approximate amount for self-installation of air suspension on domestic cars will be about 30 thousand rubles.

Factors that contribute to the installation of such a system on a car include:

a modernized truck or van is regularly used to transport valuable equipment that needs to be protected from shaking, vibrations and possible damage due to road irregularities;
there is frequent transportation of goods, the mass of which is close to or higher than the permissible loads on the standard suspension;
a higher level of comfort or safety during transportation is required.

The decision to re-equip the car in this part is made by the car owner independently.

What happens when installing pneumatics

The owner of the car, who has decided to install an air suspension, must understand that by this action he introduces technological changes into the design of the car. Such actions are quite reasonably capable of causing official dealers to refuse further warranty service.

In most cases, the basic elements of such a suspension (air bags) are fixed using special brackets, while all adjustments are made from the remote control installed in the car.

In a simplified version, pneumatics is installed without the possibility of mobile control. For such situations, adjustments to the level of air in the cylinders are carried out using nipples, as well as when monitoring the pressure in car tires. The principle of installation will be the same as in the adjustable version, and the overall reliability of the installed system depends on the quality of the air bag.

When choosing manufacturers of pneumatic equipment for cars, you need to focus on the leaders in this field: Firestone, Factory, Dunlop.

Proper selection of equipment

Interfering with welding work in the design of a standard suspension, there is a risk of partial weakening of the structure. Such work must be carried out taking into account this fact. The installation should not provide deterioration of access to the "native" shock absorbers or air springs, so that it is possible to replace them if necessary.

Air springs must be selected based on the design features of the car. Often, bellows or sleeve models are chosen for the rear axle. Geometric parameters are selected according to the characteristics of pneumatics, which can be single-circuit or double-circuit.

For long cars, it would be preferable to use a pair of circuits: on the front and rear axles. In this case, the following set is used:

a pair of containers for pneumatics having an identical volume;
transitions, fittings and plastic pipelines for air distribution;
mounting brackets, mounting accessories;
pressure gauges for each axle, start buttons, compressors, etc. are mounted in the circuit.

The optimal kit allows you to withstand a load capacity of 1.2 ... 1.4 tons, which is one of the most popular parameters for medium-sized vehicles.

The rear axle, as a rule, is mounted without the use of a receiver, providing greater smoothness. Installation of pneumatics should be carried out further from the springs in order to eliminate friction on its surface. On the front axle, mounting is carried out on the spring itself.

Installing pneumatics on a VAZ

It will be possible to improve the standard suspension on the domestic "classic" with the help of pneumatics. To do this, do-it-yourself air suspension is mounted on a VAZ.

Air suspension is an indispensable element if the driver needs to raise or lower the car for a while. This tuning method is great for Russian roads, because in the city the car's ground clearance can be significantly reduced, and on rough terrain it can be increased.

1

Among beginners in tuning, there is an opinion that such a complex structure as it is best to buy it ready-made. But the cost of such an element often exceeds several tens of thousands of rubles. In this case, those who want to improve the car have no choice but to assemble the part with their own hands. To begin with, we will decide on the spare parts that are included in, after which we will deal with the suitable parts for its manufacture. So, the set includes:

racks;
pillows;
receiver;
HBO valves;
tubes;
compressor;
manometers;
control device.

The only disadvantage of spare parts from the "nine" is the large dimensions

Air suspension on a VAZ can be created from various spare parts. We will list the most suitable and reliable items. The first part that makes up the system is the racks. It is best to buy new oil parts from a domestic manufacturer SAAZ. Racks should have 2 "donuts" - chippers. The latter are designed for installation on the shock absorber rod. The average cost of a set of spare parts is approximately 7500 rubles. Pillows will be mounted on top of the racks. Parts from trucks of the concern have high reliability Scania. We advise you to buy pillows from models of the 4th generation.

As a receiver, a gas cylinder from the model is suitable VAZ 2109. Firstly, this element can withstand a fairly high pressure, up to 21 atm. Secondly, it is initially equipped with a check valve, so you don’t need to invent anything extra. Thirdly, the cylinder has a 45-liter volume, which guarantees a high speed of lifting the car.

The only minus of the spare part from the "nine" is the large dimensions. If you want to save space in the trunk, you will have to use a 25-liter bottle from KAMAZ. However, in this case, you need to weld fittings and mount a check valve. In this regard, a spare part from the "nine" is the best option. Approximate cost - 2 thousand rubles. 4 solenoid valves are also required for operation. Two of them will work for reset, and the other 2 for front-rear inlet. Take valves that can easily withstand a pressure of 25 atm. Price - about 300 rubles. a piece.

2

The next indispensable elements are tubes. PVC pipes from the brake system of any truck are best suited as these parts. The cost of spare parts is about 200 rubles. The compressor is one of the most important elements of the system. Therefore, his choice must be approached with great responsibility. In many cases, drivers use a compressor Berkut R20. It has a high pumping speed and long service life. According to these parameters, analogues from this price category are noticeably inferior to this model.

The main components of the air suspension on the VAZ

The system control device consists of three toggle switches. The first three-position toggle switch should be on the left - it is responsible for turning the rear circuit on and off. The second three-position toggle switch is located on the right and is responsible for turning the front circuit on and off. The third toggle switch - the middle on-off switch - turns the compressor on and off.

When creating a system, do not forget about pressure gauges. The first of them must be placed between the receiver and the compressor. In addition to the pressure gauge, a moisture-oil separator should also be located in this part. A few more pressure gauges should be located in the passenger compartment - they are designed to control the pressure inside the circuits. Where exactly to install them, decide for yourself. The main thing is that they stand in a conspicuous place, and you can easily monitor the indicators. The cost of one pressure gauge is about 100 rubles.

3

To install the system, you will need to use the services of a turner. If there is a lathe at hand, and you have little experience in working with it, then you can do everything yourself. Wash your pillow first. Initially, it has a diameter of 4.5 cm. In order for the part to “fit” tightly into the shock absorbers, the diameter must be reduced to 4 cm. The second option is to machine adapter bushings. In addition to machining this part, you must also fabricate washers of the correct diameter for the seal.

To install the system, you will need to use the services of a specialist

In the second step, remove the spring cups located on the front "boots" - the body of the front struts, in which the shock absorbers are installed. The cups in the back must first be lowered and then cut off. Drilling additional holes for installing racks is not necessary. To do this, use the drainage holes. Remove the rubber plugs and push the hoses through the holes. Further, the hoses are fixed with plastic clamps. The rear contour must be brought over the beam at the rear of the car. In the same part, you will need to remove the hoses from the pillows. Fix the HBO valve to release air and reduce the clearance of the car on the bracket where the gas tank is attached.

At the same time, do not forget to leave a small part of the hose in reserve. To prevent the hose from dangling, it must be fixed to the shock absorber with clamps. When working on the front circuit, you will need to run a hose through the entire body of the car, fasten it to the tube, then to the stabilizer, and then to the front shield. Route the hoses of the front cushions along the steering rod, bring them into the engine compartment and put the crosspiece. Then make the wiring of the hoses, install the air release valve and the HBO valve.

After that, you need to assemble the control system. Connect toggle switches through relays using fuses and wiring. After that, fill the system with air, not exceeding a pressure of 8 atm. To check for an air leak, you need to close the garage and try to hear the hiss. After that, dissolve a little soap in water and grease the joints of the system elements with a solution. If the system has passed the test, you can proceed to testing its operation.

4

The air suspension on the VAZ requires setting parameters such as pressure and camber of the car. For optimal operation of the system, the pressure inside it should be within 8 atm., Since the pillows in the front part are able to fully open at a rate of 7.5 atm. This is mainly due to the large weight of the front of the car due to the location of the motor in it.

Air suspension requires adjustment of the machine's camber

The rear of the car is lighter - 6 atm is enough to open the pillows. Behind the brand compressor Golden eagle you need to constantly monitor, otherwise it can pump up the system up to 10 atm., Which can lead to rupture of hoses or breakage of fittings. To do this, you must constantly use a pressure gauge. The ideal is the operation of the system, in which it itself falls in a few weeks or a month.

The camber of the undercarriage equipped with the system must be set in the normal position. Initially, set the parameter based on the height at which your car most often stays, since in the lowest position of the car, the camber will be positive, and in the highest position it will be negative. In no case do not forget about this while driving, since the speed and handling of the car depend on this parameter.

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Today, the possibilities of automotive technology are constantly growing. Updates of existing components are regularly made and existing technologies are improved. Air suspension is an essential attribute of high-quality tuning.

In addition to technological capabilities, it allows you to change the body design of familiar models. After the advent of air suspension, it has become widespread in French concerns. Innovators appreciated its capabilities.

Among the most significant are the following:

Possibility of artificial regulation of road clearance. In addition to the connection between the clearance and the load on the car, the suspension allows you to increase the speed of the car, since the center of gravity of the object moves lower;
The driving comfort is improved. Installing traditional shock absorbers forces owners to choose between ride comfort and stiffness. The pneumatic system is a combination of the best qualities;
Increases resistance to increased loads. By adjusting the suspension, the likelihood of mechanical damage to the body is significantly reduced. The chassis retains its original appearance and the car does not lose control while driving.

On the video - air suspension for any car:

What does it consist of

The air suspension consists of the following elements:

How does it work / why is it needed

Installing an air suspension involves replacing the usual springs with air springs. The latter are hard plastic containers. Their pumping allows you to adjust the height of the car, which mimics the springs.

Modern systems have electronic components and sensors, which are a significant advantage. All-metal suspensions are not able to instantly adjust and adapt to bumps in the road.

The primary task of pneumatics is to quickly adjust the distance between the bottom of the machine and the road surface. It has gained the greatest popularity among owners of domestic cars. But you can read about how it happens in the article at the link.

On the video - how the air suspension works:

How effective is it when used

Has high efficiency. During operation, malfunctions rarely occur, and fast clearance allows you to save running elements.
It is advisable to use the suspension for regular transport of goods and movement on bumpy terrain. Ride comfort is improved, travel speed is increased and controllability is maintained.

Do-it-yourself or factory-installed pneumatics are undeniably superior to metal springs.

How is the installation by hand

Installing an air suspension on your own will require careful study of each element. The most difficult step is installing the plastic cushions and removing the shock absorbers.

The installation process looks like this:

Dismantled front suspension. The body is bored to install the cylinder. It is allowed to adjust the diameter of the containers. ;
The air supply fitting is protected;
Tubes are installed for subsequent connection to the cylinders and the receiver;
After fixing the compressor, electrical wiring is laid.

On the video - the installation process with your own hands:

Which is suitable for any "car"

There are several options for air suspension:

There are varieties of suspensions designed for certain models. Dual-circuit pneumatics is installed on most cars and is considered the best combination of financial costs and quality.

Price

The cost of suspension in the domestic market varies from 40,000 to 50,000 rubles.
Pneumatics for domestic cars is the cheapest. Its price is no more 70000 rubles.
The e-f class cars are the most expensive - from 80.000 to 100.000 rubles.

Which one to choose

Before purchasing a suspension, it is recommended to determine the functional purpose of the car. The owner of a gazelle will need to increase the payload without compromising control on the road, the driver of a racing car needs more performance.

For installation on a VAZ car, a two-circuit system is best suited.

For a sedan, a four-circuit air suspension is suitable.

The height of the pillows should be less than 250 millimeters, and the capacity of the receiver should be 8 liters.

From Airride

In the assortment of this line of air suspensions there are many different models:

The company is distinguished by high quality and affordable prices. Products perform all the tasks and have a long service life. Own production allows you to level the cost of intermediaries, thereby reducing the retail price.

Paying tribute to fashion, the air suspension becomes one of the paraphernalia of the car. The direction of stance is becoming more and more developed, in which, without owning an air suspension, but let's say a screw suspension, the use of a car in everyday mode becomes more difficult and uncomfortable.

Air suspension is installed not only by connoisseurs of new tuning trends, but it can also be very useful in the everyday life of an ordinary average driver.

Let's take a look at the main pros air suspension:

The ability to adjust the ride height (you can improve the patency of your car despite its lower class)
Handling and roll (It is worth noting that despite the smoothness of the ride, unlike the springs, you can change the behavior of your car in a matter of seconds by adjusting the pressure)
Drawdown when loaded (you can adjust the height of the car regardless of its load)

The pluses include many more factors that satisfy the needs of the car owner.

To the main cons can be attributed:

Initial installation costs (since your car was not previously equipped with this function, it will be necessary to spend money on the purchase of all units)
The service life of the air suspension due to external factors (frost, reagents, etc.) is much less than that of springs.

Main types air suspension:

Double-circuit - the ability to separately adjust the height of the front and rear of the car.
Four-circuit - control each airbag separately, while they are connected to each other by means of an electronic controller for dynamic and static control (it is a more expensive option).

As for airbags, they also exist several types:

Air suspension components

Production of air struts

Before manufacturing air struts, it is necessary to decide on the choice of pillows, based on the weight of the vehicle and the diameter of the springs.

It is also necessary take into account the location of the spring(separately from the shock absorber, or the shock absorber in the springs).

For passenger car The most common and versatile are Rubena 114x2, 114x3, 130x2 and 130x3 air bags.

For heavier vehicles, the Dunlop 152x2, 152x3 and Rubena 170x2, 170x3 models are suitable.

For the manufacture of air struts, we need machined flanges and braces for attaching air bags.

Flange for welding (for rack, shock absorber).

On sale on the sites there are ready-made flanges for the diameter of the air bag, as well as ready-made semi-sets. Flanges for the diameter of your pillow and rack can be ordered from the turner.

The bracket can be of a blind type (photo No. 1) (if the shock absorber is located separately from the air bag), or with a hole in the center (photo No. 2) for the shock absorber shank (if the shock absorber is located inside the pillow).

photo #1

photo #2

A platform for a spring is cut off from the rack and a flange is welded under the pillow.

A brace is put on the pillow.

And it is tightened to the welded flange on the rack, with the help of bolts. From the top, a bracket is also put on the pillow and attracted by bolts to the flange, from the top a rubber seal is put on the rod.

Ready air strut.

If the rear shock absorbers are installed in the springs, then the manufacturing process is similar.

If the rear shock absorber is separate from the spring, then the manufacturing process becomes easier. You don't have to boil anything anymore.

Ready rear airbag (provided that the shock absorber is separately).

Once air struts have been manufactured, they must be checked for air leakage before installation. After checking, it remains to remove the old suspension and install a new one, stretch the hoses, wires, and connect the control unit.

Installing an air suspension in specialized centers will cost a lot of money, ready-made pneumatic kits or components, and installing it yourself will save you at least half of the budget.