Custom Delrin/UHMU Shackle Bushing Replacement - 4th time is the charm?

The 4th time is the charm? When we "upgraded" our leaf springs to Deaver custom springs, we preemptively replaced our shackles and bushings with new ones too. But ever since the new springs, we've been going through shackle bushings like tic tacs... The 1st set lasted until Baja, the 2nd set lasted until Oaxaca 🇲🇽, The 3rd set was done by Panama 🇵🇦
Thankfully one of our supporting channel members, Boxer Metal, offered to turn me 2 sets of custom Delirin and UHMW bushings with shoulders which hopefully are more durable...
This is that Story.
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[@canterburyfour]

Glad they fit. I hope they last longer.

[@Everlanders]

I can't thank you enough for making these for us!

[@gladdingman]

good job dude

[@JockeSelin]

Boxer Metal, thanks for helpin’ Everlanders out (or is that oot?)! 😎👍🏻

[@tomdudley2087]

At 1:08 in your vid, if the truck had its weight on the suspension, the position the shackle is to far back. I.E. that's the position of partially compressed suspension. The shackles length doesn't give much of spring lengthening. Those are quite a high arch spring, and that amount of travel is eating up all the swing the shackle can give. Longer shackles could help a little, but if you are going to go to that expense the rear hanger should be moved back about an inch so the shackle at least starts from a neutral position. Or you could have a new main and wrap leaf put in that's a bit shorter to the rear. It needs to straight up ( or even slightly forward, 1/4" )when the truck is normally loaded, so that the shackle can swing far to accept the longer length of the compressed spring.40 years ago when I did this stuff for a living this was a common problem with lifting 4x4's using high arch springs.

[@Everlanders]

I hear you Tom, Here's whats up: kzbin.info/www/bejne/nKfGg4JtbbCVmJo

[@sickjohnson]

What a legend Kristoff is and the machinist too! Good luck with the new Delrin bushings!

[@Chris-ut6eq]

very glad you had a helping hand! Seems like the beast has a small chronic health problem but has a solid doctor to care for it.

[@samuelmora79]

Yo me los encontré, estaban en santa Elena en un hostal y por eso los pude conocer ❤️❤️

[@Everlanders]

Fue un gran placer conocerte.

[@homedad3324]

Just did the alxe and bushings on my Boler. Your livin the dream!!

[@4ourE]

Nice work Jon! Hopefully all goes well with these bushings and you’ve cured this lingering problem!

[@robertburgess6100]

You do what you have to when doing on the road repairs! Good job.

[@TomLentz]

Nice job! The delrin was probably the right call. Global West makes some "del-a-lum" bushings which are delrin with aluminum sleeves. I've used them on muscle cars in the past and they really work well. They have grease fittings too.

[@Everlanders]

That's reassuring, but 😲😲😲 🤑🤑🤑

[@anthonymarino4260]

I will be fine the scenery will make worth while well done

[@johnkaufmann4711]

Glad you're friend come to help . Congrats on getting it fixed .

[@Everlanders]

Here's hoping!

[@99Jeep2008]

Great job!

[@ChaoticEko]

Thanks!

[@CITAP1]

Brutal what happened to those bushings . I'm surprised there wasn't similar wear shared by any of the others. Only thought on the new bushings is, with the outside edges engineered to take up the gap that is normally there from side to side, will that cause or amplify an issue. For some reason the rubber is being ejected out a side. Now there is no way for that to happen. That force still exists, how will it manifest itself now? I hope this fix does what is hoped for and resolves the problem. Take care.

[@BroodPitt]

Great work! I like the engineering style!

[@Everlanders]

Hopefully it lasts...

[@gladdingman]

super curious how this holds up, as always great video and safe travels

[@courtlandbrewster7708]

Fantastic as always. Glad no accidents with the high lift and jacking arrangements. Can be a lot of stored energy release if the force support arrangements slip.

[@Everlanders]

Oh yeah, we were operating at full pucker...

[@mikemckeever8749]

In normal operation, both bushings in a spring shackle should be seeing exactly the same loads, and failing at about the same lifetime. If one of the bushings is failing regularly while the other is fine, the failing one is seeing much greater loads. This could be due to the shackle bottoming on something close to the failing end and therefore seeing increased loads due to leverage. I would think that this sort of contact would leave some wear or marks on the contacting parts and stress those parts considerably. Longer shackles, if they would fit, might or might not remedy the situation of having springs that are longer when fully compressed. It would be instructive to load the back end of the vehicle down to the bump stops and examine the shackle geometry. My best guess at a solution is to move the spring hangers aft some clever distance, like the difference in the arc lengths of the OEM and the aftermarket springs. Rubber bushings are used in suspensions for their ability to flex rotationally without need for lubrication. Some shock absorption is a side benefit. Replacing the OEM rubber bushings with a non-elastomeric material defeats this property and will either wear and squeak or require some regular lubrication. The predecessor to rubber bushings was bronze bushings that rotated on a shaft and required grease fittings and regular greasing.

[@blaynepaquette7613]

Glad to see those Brake hoses are still holding up. Unfortunate luck on the suspension though.

[@sirculito15893]

Great great job. Let's hope it holds. If you pass by Argentina, specifically Cordoba, Mendoza or San Juan, I would like to help or invite you to a Argentinean "Asado" Safe Travels!

[@ogaddcb]

Great video again. Around 07:50 I see some LED driving lights in your grill. I’m having all kids of trouble finding LED driving lights that DO NOT interferer with my radio. Yes I’ve tried ferrite core pseudo-filters with no success. . What brand LED do you run?

[@Everlanders]

Those are generic Mexican truck stop strobes...

[@jcf6597]

I hope I'm wrong for your sake but I can't see the delrin bushings lasting very long. I agree with your other viewer that you need a longer shackle and you'll probably have to fabricate a new rear spring hanger with more drop to accommodate the new longer shackle eventually in order to have a longer lasting repair. Either way I enjoy your videos and keep them coming.

[@Everlanders]

I hope your wrong for my sake too! 🤣🤣 But if they fail again, I'll look into longer shackles and hangers as you say.

[@kurtford4862]

Hello Everlanders I have had the same problem with my 7.3 with Dever spring pack after I mounted custom camper box ,the problem lies in how you mounted the box to the frame this comment page doesn’t give me room to explain in detail but I fixed the problem twelve years ago and haven’t had a problem sense.makeing longer shackles will only make the problem worse.The box should be mounted solid on the rear and free at the front with a combination of springs and rail guides the articulation should be happening in the mid section of the vehicle Fords frames are a “C” channel and are by nature twisty.After I made these changes my truck felt a thousand times better and enabled me to go to places I couldn’t go before think of it like the bed of a dump truck mounted solid in the back and free at the front . On mine the problem seem to be mostly on the driver side I would actually snap the shackle in half let me know if I can help or send pics of what I did

[@Everlanders]

Our box does in fact articulate as yours does, we use air springs and rail guides... still I'd be happy to receive any photos you have. Jason at Everlanders comma

[@kurtford4862]

I have tried to reply with photos to your reply but no go no address found

[@EdsPlace]

What type of spring mounts do you use?

[@Sylvan_dB]

Delrin seems good, but the shoulder breaking on that one... Maybe too brittle for the forces that are destroying the rubber? I might have done one side delrin and the other UHMW plastic for comparison. One might be better, or both might get trashed. I wonder if there is a more heavy duty bushing or perhaps a slightly longer shackle to go with the greater load and longer springs.

[@Everlanders]

Again, I can't really make a longer shackle unless I also fabricate frame perches, this would involve dropping the fuel tank, and possibly lifting off the box... I had a suspicion that's Delrin might be too hard, that's why I was very happy when Chris at Boxer Metal found a scrap of UHMW... However high-end racing cars have Delrin bushings, so I'm giving these a chance, can always do it again, I'm getting good at it...

[@jollyjrog3r]

What would be a permanent fix for this? Longer shackle? Different springs?

[@Everlanders]

Our best guess right now is longer shackles, but that's hard to do because of the way they are inverted, they would hit the bottom of the camper box. I would probably need to fabricate a dropped hanger too. What I should have done and may still do is fasten a GoPro there and hit some big bumps. The slow motion video will show if the shackle is running out of swing.

[@gonzalez7805]

Maybe lower the bottom mount to make room for longer piece?

[@Everlanders]

Exactly

[@carlosvogel12]

Do this ones don’t need some kind of grease?

[@Everlanders]

They shouldn't, Delrin is pretty slippery stuff...

[@davidpatrick1813]

Are ya'll okay ? no hear from for over a month. ... do we need to send the posse?

[@Everlanders]

We're good... The newest videos can be found here: kzbin.info/aero/PL0uBLqOOwG8iQo1QR74MBbUshZk6FOKfX

[@davidpatrick1813]

@@Everlanders good news, think on these things ... drive safely ...

[@cooltropolismodelrailroad9101]

move the shackel mount back 13mm or so ... isnt bolted to the frame. need a good drill and some harden bolts.If you say it real fast it sounds easy so you got this in the middle f nowhere in another country with limited tool.... goood luck

[@Everlanders]

Like this: kzbin.info/www/bejne/gp-nk61tpNWopqs Didn't help

[@Solvefunction]

still holding up?

[@Everlanders]

Nope, this: kzbin.info/www/bejne/pInQpZqQe7-smsk And this: kzbin.info/www/bejne/gp-nk61tpNWopqs

[@Van-..-z._-_z.-._-._.-z.]

What are you favorite places in the U.S.?

[@Everlanders]

goo.gl/maps/Kb2mDNJe97QJvFYD9 goo.gl/maps/nVzcakQ2U1PaPtc67 goo.gl/maps/yXujdgotEeo7jSJa6 goo.gl/maps/AFv9bktc43bke7pR7 goo.gl/maps/ZQKsn9HZBwNN3Wjv6 That is all...

[@comfort_in_discomfort]

Longer bump stops.

[@Everlanders]

Longer Shackles.

[@comfort_in_discomfort]

@@Everlanders I know. But you said you were limited on the travel due to the composite. I thought limiting compression might be an opportunity to reduce wear on the shackle - and likely won't impact your performance at all, as the damage likely occurs at the veeeery end.

[@Everlanders]

But I don't want to limit my travel or articulation. If these fail again I'll have to look into lowering the cast hangers.

[@comfort_in_discomfort]

@@Everlanders I think you can simulate the exact condition that's causing the wear. Find a ditch, and cross diagonally. Load the driver's rear. I bet you won't have to limit articulation much. In order for that shackle to only damage the bushing means that it's really only at the very limit of articulation anyway. Just a thought.

[@yougear100]

What!?!? No test drive? I hate cliff hanger endings.

[@Everlanders]

I'll let you know in 10,000km

[@yougear100]

@@Everlanders My fear is that the crack in the plastic will cause a stress fracture. Hope it all works oot. 10km? That's that European Canadian thing again. Right? What's that? Like 50 miles?

[@carlyellison8498]

Use OEM PARTS ONLY.

[@Everlanders]

I am the OEM!

[@sideburnie]

singing along... "time to do some sketchy shit, dooo dah, dooo dah" ... jesus holy christ those are smoked. bummer about the shackles maybe being too short...

[@Everlanders]

I think I can stretch the shackles 3/4" or 1" ... If these fail, I will likely try that.

[@spencervidal3168]

Urethane bushings work for me

[@Everlanders]

Is your rig greater than 16,000lbs?

[@spencervidal3168]

@@Everlanders No, you have me there. But I fear that the Derlin will be to brittle.. Keep me posted.. I am curious how that will work.