Flat Out Engineering offers a range of suspension kits designed for do-it-yourself builders, focusing on ease of installation and compatibility with existing vehicle components. These kits are tailored to reduce the complexity of suspension upgrades, ensuring that users with varying levels of mechanical expertise can complete installations with the right tools and guidance. This article provides a detailed exploration of the installation process, welding requirements, and component compatibility for both front and rear suspension kits.
Installation Process and Design Philosophy
Flat Out Engineering kits are engineered to simplify the installation process for the average home builder. The company emphasizes the importance of minimizing modifications and ensuring that components are designed to work with stock parts whenever possible. For example, several rear kits, such as those for the Ford F-100 and ’55-’59 Chevy P.U.’s, are described as complete bolt-on kits. These require minimal effort, typically limited to drilling a few holes for proper fitment. Other rear kits are partially bolt-on but may require welding for crossmembers or boxing plates.
For front suspension kits, many include boxing plates that must be welded to the frame rails. The crossmember must also be welded to the frame, and all upper and lower A arm and control arm mounts, along with the rack and pinion mounts, are prewelded to the crossmember. This prewelding creates a one-piece crossmember, eliminating the need for users to calculate geometry or install separate upper top hats, which can be challenging to align correctly.
Despite efforts to reduce welding, the manufacturer acknowledges that proper welding skills are essential for a secure and safe installation. Instructions provided with each kit include detailed guidance and necessary hardware, such as nuts and bolts, to facilitate the process.
Compatibility and Component Availability
A key design consideration for Flat Out Engineering kits is the use of standard GM parts for critical components such as ball joints, brake parts, and tie rod ends. This ensures that replacement parts are readily available at any parts store, making long-term maintenance and repairs more convenient and cost-effective for users. The availability of these standard components is particularly beneficial for those planning to use their vehicles for extended periods and over long distances.
However, some kits require the use of specialized components. For example, the narrowed front kits, such as those for the ’35-’40 Ford models, cannot use the stock rack and pinion unit. Instead, Flat Out Engineering offers new power or manual, narrowed rack and pinion units specifically designed for these applications. This customization allows for a better fit and improved performance in vehicles with modified or narrower wheelbases.
For most applications, the stock Corvette power rack and pinion steering unit is used. This component is designed to work well with the Corvette suspension and provides a good steering ratio without bump steer. If the existing unit is in good condition, there is no need to replace it. However, if the unit is damaged or worn, new units are available for purchase from Flat Out Engineering.
Welding Requirements and Recommendations
Welding plays a significant role in the installation of both front and rear suspension kits. While some rear kits are fully bolt-on and require minimal welding, others necessitate the welding of crossmembers or boxing plates. Front suspension kits often include boxing plates that must be welded to the frame rails, and the crossmember must be welded to the frame as well.
The prewelded crossmember design for front kits streamlines the installation process by integrating all upper and lower A arm and control arm mounts, along with the rack and pinion mounts, into a single unit. This one-piece crossmember eliminates the need for users to calculate and install individual components, reducing the potential for misalignment and ensuring a more secure fit.
Despite these design advantages, the manufacturer emphasizes the importance of having proper welding skills or access to someone who does. This recommendation is based on the critical nature of suspension components in ensuring vehicle safety and performance. Poor welding can lead to structural weaknesses, which may compromise the integrity of the suspension system and, in turn, the safety of the driver and passengers.
Kit Components and Assembly
Each Flat Out Engineering suspension kit comes with detailed instruction sheets that guide users through the installation process. These instructions include step-by-step guidance on how to assemble and install the components, as well as information on the necessary tools and hardware. The kits also provide all the required nuts and bolts, reducing the need for users to source additional fasteners separately.
For rear kits that require welding, the instruction sheets will specify which components need to be welded and how they should be aligned with the frame. Similarly, front kits include instructions on how to weld the boxing plates and crossmember to the frame rails. The detailed nature of these instructions ensures that even builders with limited experience can complete the installation with confidence, provided they follow the guidance accurately.
The inclusion of prewelded components in the front kits further simplifies the process. By eliminating the need to install separate upper top hats, the one-piece crossmember design reduces the risk of alignment issues. This approach also minimizes the amount of welding required, making the installation more accessible to builders who may not have extensive welding experience.
Safety and Quality Considerations
Safety is a key concern in the design and installation of Flat Out Engineering suspension kits. The use of standard GM parts for critical components such as ball joints, brake parts, and tie rod ends ensures that these parts meet industry safety standards and are readily available for replacement if needed. This reduces the risk of component failure due to wear or damage, which can be a common issue in older vehicles or those subjected to frequent use.
The prewelded design of the crossmembers and the emphasis on proper welding during installation further contribute to the overall safety of the suspension system. A well-welded suspension ensures that the components are securely attached to the frame, reducing the likelihood of structural failure under stress. This is particularly important for vehicles that will be driven over long distances or in challenging driving conditions.
In addition to safety, the quality of the components used in the kits is also a consideration. Flat Out Engineering uses high-quality materials and manufacturing processes to ensure that the parts meet the required performance and durability standards. The company’s focus on minimizing modifications and using stock parts where possible further enhances the reliability and longevity of the suspension system.
Customization and Special Applications
While many Flat Out Engineering kits are designed for standard applications, the company also offers customized solutions for vehicles with specific requirements. For example, the narrowed front kits are tailored for vehicles with modified or narrower wheelbases, such as the ’35-’40 Ford models. These kits require the use of a narrowed rack and pinion unit, which is provided by the manufacturer as a replacement for the stock unit.
The availability of both power and manual rack and pinion units allows users to choose the option that best suits their vehicle’s configuration and their personal preferences. This level of customization ensures that the suspension system can be adapted to a wide range of applications, making it a versatile solution for different types of vehicles.
For vehicles that require a more traditional or classic suspension setup, the company’s focus on using stock GM parts and minimizing modifications makes it easier to integrate the kits into existing systems. This approach is particularly beneficial for classic car restorations or custom builds where maintaining the original appearance and functionality is a priority.
Maintenance and Long-Term Use
The ease of maintenance is another important consideration for Flat Out Engineering suspension kits. The use of standard GM parts ensures that replacement components are readily available at parts stores, reducing the time and cost associated with repairs. This is particularly advantageous for users who plan to keep their vehicles for many years and may need to replace worn or damaged components over time.
The prewelded design of the crossmembers and the emphasis on proper welding during installation also contribute to the long-term durability of the suspension system. A well-installed and properly maintained suspension can provide reliable performance for many years, reducing the need for frequent repairs or replacements.
In addition to regular maintenance, users are encouraged to follow the manufacturer’s recommendations for inspecting and servicing the suspension components. This includes checking for signs of wear, corrosion, or damage and replacing any parts that show signs of deterioration. By following these guidelines, users can ensure that their suspension system continues to perform optimally and remains safe for use over the long term.
Conclusion
Flat Out Engineering suspension kits offer a comprehensive solution for DIY builders looking to upgrade or replace their vehicle’s suspension system. The company’s focus on ease of installation, compatibility with standard components, and the use of prewelded parts reduces the complexity of the installation process, making it accessible to a wide range of users. The availability of both bolt-on and partially bolt-on kits, along with customized options for specific applications, ensures that the kits can be adapted to a variety of vehicles and requirements.
The emphasis on proper welding and the inclusion of detailed instruction sheets further enhance the reliability and safety of the suspension system. By using standard GM parts and minimizing modifications, the kits provide a cost-effective and durable solution for long-term use. Whether for classic car restorations, custom builds, or modern vehicle upgrades, Flat Out Engineering kits offer a versatile and user-friendly approach to suspension installation.
For users considering an upgrade, the availability of replacement parts and the ease of maintenance make these kits a practical choice. With proper installation and regular maintenance, the suspension system can provide reliable performance for many years, ensuring a smooth and safe driving experience.