DIY: Coil bags - protect your coilover suspension

[omahasubaru]

I did this write up over on RS25 in 2010... Figured it may be nice to have over here too.

This is a DIY for making your own coil bags. These are covers that go over your coilover springs to protect everything from debris, dirt, grime, etc. They are most commonly used on open wheel off-road applications such as baja type vehicles as well as every day ATVs. They have gained in popularity for stage rally applications over the past few years.

I decided to make my own as I was unable to find very many off the shelf options. DirtBagz (http://www.dirtbagz.com/db_main_pages/db_main.htm) makes some as do a few coilover companies.

Here is what we're looking to make. *this is my first DIY, so bare with me

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4531JPG-1.jpg


Materials you will need:
- canvas material from a local fabric store.
- heavy duty thread
- heavy duty velcro
- some rope/string or zip ties
EDIT: I went with craft wire for a more sturdy choice and just twist tied the ends. I would not recommend string or zip ties in this application.


Tools you will need:
- fabric tape measure
- scissors
- pencil or fabric marker
- sewing machine


Other items that may be useful:
- spare fabric to use for your first template
- ability to use this DIY as a guideline and interpret/adjust as needed.
- a measure twice cut once mindset
- patience
- skill with the sewing machine, or a friend who does


Here we go.

[omahasubaru]

Phase One : Building a template

There are a few ways to do your covers. I'm only going to cover the two more popular ways.

1) Measure your springs and perches

You'll want to use the fabric tape measure for this. Measure around the widest part you want to cover. Sometimes this is the upper or lower perch, other times it is spring. Especially if you have some of the newer Hypercoil OBD springs. Take this measurement and add around 1.25-1.5" to it and write it down. This helps to account for overlap and velcro strip.

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4666JPG-1.jpg https://sl-i.net/FORUM/images/imported/2012/02/IMG_4667JPG-1.jpg


2) Measure your coilovers for the length you want to cover.

This is where options come in. You can either measure from above the upper perch and just to below your lower spring perch, or you can measure all the way down to the knuckle ears if you want. Neither way is wrong, but I prefer the latter, as it covers any remaining exposed un-used threads you may have. Please be aware that not all struts are the same length. You rears will likely be longer than the front, so you may have to make two patterns for best results. Write down your measurements.

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4668JPG-1.jpg

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4524-1.png (http://picasaweb.google.com/jon.d.simmons/DIY?authkey=Gv1sRgCMnJpKWznoaX9AE#5535052912373060498)


3) Build your template

Take your measurements and use the guide here to add to them. You have to add to account for folding over and stitching. This also gives you just a little more length depending on how good your measurements were. Your measurement goes on the inside of the lines in the template below.

https://sl-i.net/FORUM/images/imported/2012/02/template_pattern-1.png (http://picasaweb.google.com/jon.d.simmons/DIY?authkey=Gv1sRgCMnJpKWznoaX9AE#5535052910957184738)

The top/bottom has a longer fold to account for room to run your rope/string or ziptie through to snug up the ends.


4) Test fit it.
It should be over-sized at this point, but this is a great time to catch any issues you may have with your measurements before you go further.

[omahasubaru]

Phase Two : Make your bags

Now we take your cut out pattern and start to put it together.

1) Fold & stitch your pattern.

Use this guide below to setup your folds and location of your stitching. You don't want to stitch the ends closed as then you can't run your rope or tie through to snug up the ends. Use the zig-zag stitch pattern on the sewing machine.

https://sl-i.net/FORUM/images/imported/2012/02/template_stiches-1.png (http://picasaweb.google.com/jon.d.simmons/DIY?authkey=Gv1sRgCMnJpKWznoaX9AE#5535052910714557986)


2) Place your velcro & stitch it on.

Use the guide below to determine where to locate it. You need to place one side of the velcro on one end and stitch it on. Then place the matching side of the velcro on the other side of the fabric on the opposite end. This is so when you wrap it, the velcro meets up correctly. Use the straight stitch pattern on the sewing machine.

https://sl-i.net/FORUM/images/imported/2012/02/template_velcro-1.png (http://picasaweb.google.com/jon.d.simmons/DIY?authkey=Gv1sRgCMnJpKWznoaX9AE#5535053420928759666)


3) Test fit it.

Now it should fit quite well and should look something like this.

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4521JPG-1.jpg

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4522JPG-1.jpg

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4523JPG-1.jpg

4) Choose your snug method.

This is where you decide if you want to use some rope/string material to snug up the ends, or zip ties. I initially went with some nylon rope, but have since had concerns about how well it would stay tied and have elected to go with zipties. My intended use for the car and the suspension is scca rallycross events and lots of gravel road use. So I really didn't want my bags to sag.

EDIT: I ended up going with some craft wire to tie up the tops. It is easily fed across the top, bent, twisted, and then snipped. It is not likely to get brittle with age like zipties. It is not easily undone like the nylon rope. It is easily repeatable, just need to bring some with me to events in the event one fails.

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4530JPG-1.jpg

[omahasubaru]

Phase Three : Repeat & Enjoy

Now you merely continue to make your remaining coil bags and then put them to use.

https://sl-i.net/FORUM/images/imported/2012/02/IMG_4532JPG-1.jpg

Thanks for checking out my DIY, I hope someone can find it useful.

[omahasubaru]

I will be making a set of these when I get coilovers on my BE this spring and will make sure to add that info here in this thread. Specific measurements to what ever setup I go with, etc.

Thanks - Jon

[mlitz]

this is awesome! I may have to do this...

[hansvonaxion]

Good idea, great DIY. Don't know if I can be bothered to do it right now (too much other stuff to do first) but I know I should.

Thanks.

[Huffer]

You might also want to either use a waterproof material, or at least spray the bags once a year with a waterproofing agent like Scotchguard.

Good writeup Jon!

[omahasubaru]

^^ good thought. I will be researching materials for the Legacy since it is exposed to DD use. My rallycross car really isn't driven all that often.

[StatGSR]

my real question is what does it look like under there now after 2 years?

[TahoeLegaSTi]

my real question is what does it look like under there now after 2 years?

I'd like to know the same.. This looks like a great way to keep things clean and prestine..

[omahasubaru]

I'll get some shots and show you guys. They have been heavily abused on my RallyX car.

[danieltrusty]

did you consider trying nylon rope with some of those things that have a spring in them that you squeeze and slide to tighten the rope/string? I don't know what they are called, but they are used alot on waist bands, back packs, etc.