Rear spring bellows with its longer bottom piston fitted to front axle. Note this shot is at maximum ride height, but there is still some travel left in the air spring.

For the rear, Hardy found that new aftermarket rear bellows were longer than OEM (see pictures on Air Spring Bellows Replacement Page) so he used these. Testing the articulation without the rear shocks connected he found he could get about another 2 inches at the shock mounts. However his search for longer shocks proved fruitless so for now he left the stock rear shocks in place. In the new higher settings he chose (see below) this only allows a couple of inches of axle droop, a problem that may be addressed later. Meanwhile Hardy notes "I've heard some concern over standard airsprings ripping off mounts when vehicle is jacked by chassis instead of axle.On my vehicle (std shockies and longer springs) this cannot happen."

He also considered lifting the rear further using spacers, and even made some up. However in the absence of a solution to the shock problem, this aspect was put on hold.

Meanwhile, Hardy replaced the 255//70 tires he had been using with 265/75s, and had new lower ratio 4.1 ring and pinion gears from Great Basin Rovers installed to compensate for the larger tire size (see page on air supply for locker and tire inflation). With the new longer springs front and rear, Hardy was able to get the EAS reprogrammed again to higher settings commensurate with the new tires and gears. The final settings were as follows:

"The new larger tires fit beautifully, just rubbing slightly on the inside of front mudflaps while turning on driveway gutters etc. Freeway mode works fine too, just rubs a little more while turning on bumps (time to go up). The plan was to go with 255/85 but I chickened out, preferring to preserve the RR good manners somewhat. 

"As it is now I reckon I have a pretty good set-up - compared with a bog stocker. With new tyres and 15mm EAS adjustment - the car sits over 2" higher in std mode (Fine for most trail work). When needed, the car can go up another 2" + while still maintaining a comfy ride (Over logs, water etc).  But only leaves a couple inches of down travel thanks to std shock. See 4th pic - front axle max height setting. I don't know what would happen to OEM airsprings & shockers with all wheels in the air!!?? I'll address the down travel thing once I get tired of playing with my rear locker....." (See page on air supply for locker and tire inflation for more on Hardy's locker installation).


Musings on Remaining Problems and Alternative Approaches

Part way through development of the Stage II system above, Hardy also considered lifting the rear further using spacers, and even made some up. "Below is a picture of 1" spacers I made for rear axle -- I had a mate use his plasma cutter for the cut out. I hadn't drilled mount holes as yet - still thinking..... The airspring and piston is ex front axle. I may end up using these spacers on the front. Dunno yet."

Spacers Hardy had made as one method of gaining a lift (Photo shows spacer atttached to lower front spring piston but original intention was to use it on the rear and gain the front lift by using rear springs).

"Rovertym make a 2" spacer kit for SLS Discovery's. http://www.rovertym.com/slsspacers.htm. It confirmed I'm on the right track. They look 'canted' -- I thought of doing this too, but discounted it as it might cause problems under compression - mis-aligning the top of the piston out the edge of bag. I even tried to imagine some sort of hinged spacer to allow for the effect of the radius arm pulling rear of airspring away from piston. But I think a 'slinky spacer' would be the way to go. A hollow piston platform with an internal coil would allow the airspring and piston to pull away from axle under extreme droop, relying on the 'slinky spacer' spring to relocate.

"The next idea is to go back to basics. 2" spring spacers all round, reset the offroad height back down a bit. Increase bumpstops by 1" or 2", then I'll aim to increase axle droop front and rear using combination of correct length shock absorbers and my longer springs. I came across this idea while trying to fit front shocks onto rear - they really have a bit too much travel for the one inch spring spacers. I have to recheck their possible fitment too - if they work.... give rear axle 5" more down travel - less 2" for compressed size / bumpstops.... they'll be one cheap & easy performance enhancement!"

Like many of our Rovers, Hardy's RR is a work in progress, and these ideas may serve as fodder for someone else's efforts.