Airbag Man Conversion Kit (Defender)- Air Springs FYI

[08Bender]

Hi All,

The following is just my experience with Airbag Man's coil replacement kit. I am posting for reference to anyone interested in the conversion (future searches) Please don't see this thread as an opportunity to explain to everyone why you think they might not be a good idea!

Car - 2009 Land Rover Defender 110
Conversion Hardware - Airbag Man front and rear coil replacement kit.
Control - Accuair e-level

I bought the spring kit from Brett at Airbag Man, they are just down the road from me. Compressor, tank, control and fittings from Glen at Airide in Melbourne.

Service from Airbag man was excellent, Brett even came to my house after a component failure to replace an item I fitted.

Airide service is also very good, postage of small items is overnight. Prices are very resonable, he also sells Airbag Man products (suggest you get prices from both places, remember ARB also sell Airbag Man)

Accuair technical support in America is about the best you can get.

Airbag Man Rear Kit - Top mount (supplied) will need to have material removed before it will sit flush in the upper spring bracket. I decided to discard the stainless strap supplied to secure the top plate and used screws through the spring mounts to secure that plate Suggest you pin punch the lower mount countersunk screw seats. This will help them lock in when tightening the nuts that secure that plate. I TIG welded mine in.

Airbag Man Front Kit - Top (P38) Cover can simply be modified if you wish to fit 1/4" BSP/NPT fittings. Just drill out 8mm push fitting and shorten the nipple by 6 to 8mm then tap, suggest you use a lathe. This will allow you to use 3/8 feed hose, compatible with Accuair. I replaced the upper plate counter sunk screws supplied with M10 studs.

You may need to flip the top pan hard rod bolt (insert from rear) to clear Terrafirma lower shock mount. Ensure long 5mm bolt that retains lower piston extension is fully recessed into extension or it may cause early bag failure as the bag rolls over it.

You will need a full Queensland work day to complete the spring replacement provided there are not problems. Conventional hand tools, a set of tall safety stands and a jack are about the minimum for tools.

Air Supply and Control. I bought near all the parts required from Glen at Airide. Make sure you ask for the HD height sensors. I have spent over 10 years in Automotive trade, this is one of the best kits you will buy. As I see, Accuair e-level is the only kit to buy. I would suggest 2 days is a minimum install time for hose, cabling, sensors, compressor, tank and the control unit itself.

Everything is custom with this kit so you will need to be handy with the tools. Auto elec however could not be simpler.

***CAUTION***

During the auto calibration of the Accuair system, total tank preset pressure (up to 200psi) will be pumped into the bags. I can tell you from first hand experience (i tried twice) that the front springs will not stay on the car. They will literally fly from their mounts onto the driveway. Looks spectacular but not cool! Use the alternate "manual" calibration process.

If you want more info or pictures let me know, I understand that Cal418 (Mick) is going to post lots of pictures and research regarding his 130. Mick has gathered a lot of info and alternatives, his Defender has a lot more axle travel than mine.

So far I am very happy with the conversion. The system is just like a P38 but much much faster and with much more ride height variation. Mine goes from the bump stops to about 4" of lift (above std height). Ride is marginally firmer in the front however I have not replaced my shocks yet. I expect it to be much more reliable that anything OEM. User control and setup options are excellent.

Kind Regards, Tristan

[MR LR]

Do you know if this system can be used on a D2, thinking it may be better than lifted coils. Also do you know what the total cost was (if you don't mind me asking).

Cheers
Will

[rovercare]

I've just had my second accuair ecu failure, that's all I know as it failed just prior to me be in the northern territory till tomorrow

[08Bender]

Hey,

I know the e-level system is very new and that the company has spent a lot of money on development. I understand the new system (e-level) has performed very well since its recent introduction! I do have the appropriate hardware to reinflate the bags should any of the suspension control system fail though. 4 Shrauder valves and a bit of hose is it.

Cost, about $4500 retail for the full system. You will do a lot better with Glen at Airide.

I know Airbag Man offer a wide variety of kits for Land Rover. I could only imagine D2 is one of them.

Cheers, Tristan

[cal415]

Matt, Interesting to hear you have had 2 ECU failures, do you think it could be water ingress from being mounted under the vehicle? this is something that has worried me, mine is mounted up in the seat box for now.

Tristan, interesting to hear about the cailibration causing another bag to go bang! I will avoid that when i eventually get around to fitting the rest of the kit. Did the bag popping off cause damage to the bellows or was it just a case of recrimping the bag back in position? this really worries me all the same as im sure the bag will see some very high pressures under load when flexed up- looks like the alternative front bags might be the go after all.

How does yours ride now with the front bags? do you know what pressure your bags are running with your current setup? i think mine are somewhere around 70-80psi in the fronts and about 40 in the rear with no extra load.

[08Bender]

Hey,

I have no idea what pressure is in the front. It must be close to yours though right? I don't really expect them to come off whilst at full droop. My highest ride height is about three inches from full travel. If that axle height exceeds that value then it should only drop bag pressure. I also expect pressure to drop as load is reduced when the axle drops away from the chassis. Fingers crossed!

Bags are not crimped onto the lower piston, just like the top they slip over a lip and pressure holds them their! Brett assures me that after a few months they will grip a lot harder than they are now.

I bought a spare front bag just incase, $160. The second bag looked fine after it popped off, that's the one I carry as a spare.

Does Rovercare have the e-level system or the old one?

Cheers, Tristan

[TimNZ]

Thanks for the writeup Tristan, I would be interested to know what the ride is like on rougher terrain such as rough tarmac, (at highway speeds), to corrugtions if you get the opportunity.

Cheers,

Tim

[08Bender]

I most certainly will, just need to change my shocks over and I'll let you guys know. From what I've seen so far the rear rides much, much better that the std rear 110 coils. They are similar to the softer LD rear OME springs.

The front is firmer but I still have a pair of OME Sport shocks installed, Airbag Man said they would be way to hard. I'll swap them in the next two weeks.

Cal415 would be able to offer a better opinion at this point as he has had a solid trip away on them, he also has much better shocks.

Cheers, Tristan

[TimNZ]

What shocks are they recommending Tristan?

[08Bender]

mmm? They haven't really suggested anything. The only thing that seemed important was that the compression rate be relatively low. Cal415 bought the shocks they had built, he is looking to get the spec's and have another set made I think. Maybe he will post the info once he gets his hands on it.

I'm just going to use Rancho 9000's and turn them down. Not ideal but the things are cheap!

Cheers, Tristan