Make a pneumatic system in a car with your own hands. DIY air suspension: Installation, Photo, Video

The topic will not contain comparisons of bagels and sleeves. High-quality Pindos air springs will not be mentioned.

Only accessibility, simplicity, cheapness.

So, we will talk about Scania cabin cushions.

Pre-made cabin cushions are definitely cool and wonderful. Finished it with a file and installed it. What could be simpler?

But what if the pillow cannot be installed in this form, if other characteristics are needed, a smaller stroke?

One of the most common problems when installing air suspension on a VAZ PP is the location of the lower bracket of the rear cushion. If you place it on a spring cup, then the plastic part of the bracket will be higher than the body of the stand and if the suspension breaks, there will be a blow to this same plastic bracket. In addition, it will not allow the car to sink lower.
Well, we saw off the cup, grind out the retaining ring and weld it 5-7 cm below the spring cup. The problem with the protruding bracket is solved, but another problem appears.

The spring cup is located at the level of the rubber profile, and by lowering the bottom point of the cushion lower, we position the bracket just opposite the wheel - accordingly, there is a chance to wipe the cushion, especially when installing wheels of larger width and diameter.
There are several options for solving the problem: installing donuts, moving the mount back up, installing spacers on the wheels, shortening the cushion and installing other braces.

Another equally common problem is the discrepancy between the inner diameter of the cushion and the diameter of the front strut housing. The same problem can be attributed to the inability to put the pillow on through the outer nut or protrusion on the stand.

This problem is also solved in different ways.

Someone sharpens plastic:

Someone makes special cases:

Well, one more option:

All of these options provide for the installation of only a full-size sleeve.

But what if you really want a short cut or need to reduce the sleeve length?
This issue cannot be resolved without solving the problem of sealing the sleeve.

In the factory version, the sleeve is crimped with a special ring. The ring has certain strength characteristics and resistance to corrosion; in addition, to crimp this ring you need a special machine (like those that crimp RVDs). All this makes the compression method almost impossible to do at home.

But there is one relatively simple way to shorten Scanian pillows.
Quote : " The process of shortening the same Scanie pillow is as follows. The elastic is cut with a knife along the edge of the metal ring. The metal ring slips out with little effort without a rubber band. Shorten the elastic band of the pillow to the required length. We put the same metal ring on the pillow and press it into place like an oil seal using a machine or press and soap solution. On Scanie pillows, it is better to shorten the pillows at the top, since they have a metal upper support.
The pillows in this photo are shortened in this way. Although the rings are also machined differently for ease of folding the pillow. New rings can be sharpened, but the dimensions must be taken from the originals."

Knowing the general principle, you can order the necessary components for the turner:

It’s not very convenient to look for a press every time to assemble and disassemble. Therefore, sealing can be done using bolted cones:

There is another way. This method is based on the connection principle of the CAMMOZI union nut for plastic tubes.

Classic tuning of a car, including VAZ cars, to a greater extent implies a change in appearance, or a minor upgrade of the engine. Not everyone takes some original or serious steps to make their own car more comfortable.

Designing an air suspension for a passenger car cannot be called a common type of modification of a VAZ car. This is due to the misconception about the complexity of installation and the low reliability of such a design. At the same time, in practice, designing and installing air suspension with your own hands does not cause any particular difficulties.

Advantages of air suspension

As you know, the French company Citroen actively used this type of suspension over the years. It was the French who appreciated the benefits of compressed air when driving a car.

In this case, the following design features can be distinguished:

Comfort. If it is impossible to install shock absorbers on VAZ cars with different settings for different driving modes, you can get a truly optimal ratio between stiffness and comfort for the car’s suspension.
Possibility of adjusting vehicle clearance. This feature not only allows you to link the ground clearance with the load of the car, but also lower it for high-speed races (in order to lower the center of gravity).
Overload resistance. Individually adjusting the suspension stiffness allows you to load an additional volume of cargo without fear of damaging suspension parts or changing the behavior of the car in motion.

The list of additional benefits that air suspension provides can be continued with other narrow features. However, each car owner can determine such advantages for himself.

DIY air suspension

So, what will it take to develop and install an air suspension model on a VAZ car? To begin with, it’s worth naming the component elements that will make up the finished system:

If you do not need to purchase additional tools, you can invest 30-35 thousand rubles in a complete set of equipment.

Air suspension on a VAZ

When designing a VAZ passenger car model, the most labor-intensive process is replacing the shock-absorbing struts with air springs. The best option is to use the original support frame housing.

The front suspension will need to be completely disassembled, and the spring will no longer be needed. To install a pneumatic cylinder, it may be necessary to bore the body, or adjust the cushions themselves to the diameter of the glass using the same turning. It is possible to manufacture an adapter, where one part will securely fit into the body in place of the shock absorber, and the second part will become the basis for installing the air cushion. These operations must be determined independently, taking into account the specific VAZ model and the type of pneumatic cylinders used.

Please ensure that the air supply fitting is protected when installed on the vehicle. The same applies to the rear cylinders.

At the second stage, pipes are laid and connected to the pneumatic cylinders and the receiver on the reverse side. We also place a receiver in the trunk and install pressure gauges. Taking into account the greater load on the front part of the car, we set the pressure in the front within 8 atmospheres, and in the rear for normal mode – up to 6 atmospheres.

Despite the additional weight on board, the compressor will have to be installed and securely fastened. As practice shows, the front pneumatic chambers have to be inflated regularly.

At the third stage, it is necessary to lay out the entire electrical part - wiring, toggle switches of the control unit, fuses. Pressure gauges are also installed. All these details are placed in each specific case individually. However, the ability to visually monitor the pressure level in the system should be constant. If you plan to frequently change air suspension modes, you should provide the ability to control the operation of the compressor from the remote control.

Security measures

After assembling the structure and further, during operation, the necessary attention should be paid to the technical condition of the entire structure. For this purpose, it is necessary to monitor the presence of air leaks at the joints of parts (valves, adapters, fittings). This can be done by ear if there is a strong leak, or with a soap solution. You need to pay attention to the readings of the pressure gauges, as well as the rate of pressure drop in the pillows. Periodically check the performance of the compressor.

Before starting to operate the machine, during a test drive, make sure there are no extraneous frictions, vibrations, or noises. Most often, problems arise with the steered wheels.

We periodically check the air supply hoses to the air suspension cylinders for chafing. Periodically pay attention to the condition of the fastening of the air supply pipes located under the bottom of the car. We also monitor the condition of the hoses themselves for swelling and damage to the tubes.

An important note will be the limitation on the level of pressure in the cylinders. Changing the previously specified values up or down in order to increase ground clearance or lower the center of gravity is undesirable. This is due to changes in the alignment angles of the front and rear wheels, which not only affects tread wear, but also a noticeable deterioration in vehicle stability.

The emergence of more and more innovative technologies means that systems are no longer so inaccurate, slow and clunky. Instead, more precise technologies are used, based on modern electronics that control everything from ride height to precise air suspension pressure, in turn offering a smooth, controlled drive. But the most important thing is that the car suspension system is often underestimated. And the most important thing is that this car unit is often underestimated. If we consider a car from the point of view of safe and comfortable movement, then the car suspension is as integral a part as the wheels of the vehicle. Shock absorbers and springs absorb the shock from potholes and bumps that the wheel hits. But know that every time you load or unload the car, speed it up or slow it down, turn it in different directions, you throw a “challenge” at the abilities of the shock absorbers and springs.

Nevertheless, for all its relevance and necessity, spring suspensions are already a very conservative option for softening road irregularities. The set of their functions is constant and does not include various types of adjustments and add-ons.

How does air suspension work?

Air suspension is a conventional spring car suspension in which the springs are replaced by air springs. Air springs are hard rubber or plastic cylinders that are inflated to a certain height and pressure. This is all done to imitate the same spring mechanisms in suspensions. But that’s where all the common signs end. When you add an on-board air compressor, sensors and electronic control systems to air springs, today's air suspension systems provide a huge number of benefits over the all-metal suspension of conventional springs. The air suspension adjusts instantly, can adapt to handle different types of irregularities in different situations and change load capabilities.

But the main feature of the air suspension is not its ability to expand its settings and functionality. Whether a manual or electronic air suspension adjustment system is installed, whether it was done by a garage “Kulibin” or by professionals from a large concern of experienced technologies of a world-famous popular brand, the air suspension both lowers and raises the car, increasing or decreasing its ground clearance. Air suspension is especially relevant among young car owners who use it in domestically produced cars.

The main advantages of air suspension

This mechanism installed on your car will perfectly cope with the task of absorbing unevenness and potholes while the car is moving along the road, and it will become much more dynamic and stable. By installing your own pneumatic system on your car, you will get a lot of advantages:

- the lateral roll of the car will become much less if the car is unevenly loaded;

The load on the suspension will be reduced as much as possible, and its service life will increase proportionally;

Your car will become much more comfortable than it was before with stock springs;

The stability of the car will increase when it is introduced into sharp turns;

The negative consequences of vehicle overload will be reduced to a minimum;

The longitudinal roll will disappear.

At the same time, the driver gets the opportunity to independently adjust the vehicle’s ground clearance, depending on the quality of the road surface and the degree of vehicle load.

Materials for creating your own air suspension

To make and install an air suspension on your car yourself, you should study some of the intricacies of this procedure and, of course, purchase the necessary parts for assembly. The first element you will need is air cushion. This is the most expensive part in the entire structure, which will be installed on your car instead of metal shock absorber springs. By pumping or deflating air into or from this air spring, you can adjust the ground clearance of your car. By inflating it, you will accordingly increase the ground clearance; by lowering it, you will decrease it. The air suspension works exactly according to this principle.

You will also need a compressor, which is the main element of the entire pneumatic system. It is necessary in order to pump air into the installed air bags. Braces and fastening elements. They are necessary for attaching the air spring to the body of your car. It’s not at all difficult to build these elements yourself, having first drawn up a drawing of the mounting location and ordered components from a turner or welder.

Pneumatic valves. One of them is designed to pump air masses, and the second is to release them. Pressure gauge. It can be applied to any that is used in various pneumatic systems.

Start button. Any button that works on the on-of-on principle will be an ideal option in this case. With its help, it will be very convenient for you to adjust the level of the air suspension directly from the inside of the car.

Air line. This is a device consisting of tubes connecting the pillows to each other, which are the basis of the air line of the entire system.

Pressure meter. It is provided in the form of a sensor located anywhere in the air line and used to monitor the overall pressure in the system directly from the vehicle interior.

Relay. It is necessary in order to start the injection compressor and open the exhaust valve.

Installing a homemade air suspension

In order to install air suspension on a car, the car should be placed and secured on a flat surface. Then, using jacks or a lift, you should hang one of the parts of the car - this will all depend on the place where the air spring is installed. Next, remove the factory springs and then prepare the installation site for the air spring mounting brackets. Afterwards, the prepared braces must be secured on pads with already installed valves. Then attach the cushions in place of the old shock absorbers.

The next stage of work will be the creation of an air line, thanks to which the functions of the air suspension will be carried out. To do this, it will be necessary to connect them together using tubes previously connected to the compressor. Then install the pressure gauge along with the sensors. Then place the start button inside the car and remove the sensor sensor.

After installing the air suspension, you can begin adjusting the entire system. To do this, pump some air into it and check what ground clearance corresponds to a certain pressure on a fully loaded car. When making adjustments, make sure that both sides of your vehicle have identical ground clearance. When the car is leveled on the site, feel free to get behind the wheel and conquer the road.

Air suspension, a solution typically used in commercial vehicles, is now slowly beginning to make its way into passenger cars. What is this thing, how is it useful and is its use justified? Let's figure it out.

Fundamentally, air suspension is an alternative to metal springs or leaf springs, that is, those elements that are responsible for comfortable movement over bumps and uneven surfaces. There are also shock absorbers, but their task is to minimize residual compression and stretching of springs. A simple example: take a spring (say, from a fountain pen) and hang a weight on one end of it. Then hold the spring by the other end and lift the weight slightly. The spring will compress. Now release the weight. The spring will compress and stretch, each time with a smaller amplitude, until it stops in one position. The duration of this process can be quite long. So, shock absorbers reduce the amount of vibration. This is also useful, but we are now more interested in springs, since it is they that prevent (subject to certain conditions) the car body from shaking while driving.

Why do you need a spring?

The general principle of a comfortable ride (in terms of shaking and swaying of the body) depends on two things: the weight of the car and the spring stiffness. Light car + stiff springs = driving like a jackhammer. Heavy car + soft springs = sea motion and suspension breakdowns. That is, we need correspondence between these parameters. But let’s say our springs correspond to the weight of the car. Yeah, but just which one? When you travel alone and without a load? Or are you carrying four passengers, each weighing 100 kilograms? Or when, in addition to passengers, you also have cargo weighing only 100 kg in the trunk? The difference in weight is significant, and the spring is not so versatile as to work correctly in all these situations. Accordingly, the spring stiffness must be changed. But how can you change the rigidity of an iron wire twisted into a spiral? No, that’s the point. And here the air suspension comes to the rescue.

Another problem associated with changing the vehicle load is body sagging. Under heavy weight, the springs are compressed and the ground clearance decreases, which on our roads, “equipped” not only with bumps and holes, but also with speed bumps made to the best of our ability, can even cause the vehicle to break down. Or, conversely, the car is designed to carry a large load and, if you drive empty, the body rises too much above the ground, the position of the center of gravity changes and the ride becomes less comfortable. And here the air suspension also comes in handy.

In this car, to install the pneumatic system, use the spare wheel niche. The lack of a spare wheel must be compensated for by having it in the car.

Who uses air suspension

Pneumatic cylinders instead of springs and springs are used in freight transport - there the change in weight is huge and you can’t get anywhere without compressed air. Here the cylinders serve to compensate for the increase in weight.

Another area of application is SUVs used both in the city and outside of civilization. A sharp difference in operating conditions requires a change in ground clearance: in the city and on the highway, where the speed is high, a low ground clearance is desirable, with which you cannot drive through the forest.

And, perhaps, the most interesting direction is low-riding, the idea of which is to lower the car to the very ground so that no hair gets through. It is clear that such a vehicle can only move on a perfectly smooth hard surface, of which there are not many. So you have to increase the ground clearance outside the venues where you can show off. And the independent air suspension on all wheels helps the cars “dance”: changing the distance from the wheel to the body makes the car tilt in different directions, and the most skillful low-riders can do this, falling into the rhythm of the music. The picture is exciting.

One pneumatic element is not enough

The working element of an air suspension, which replaces a spring or spring, is, in essence, a rubber bag (also known as an air spring, also known as a pneumatic element, also known as an air bag) with a hole through which air is supplied or pumped out. Everyone knows that the more you inflate such a product, the more rigid and resistant to compression it becomes. It is this bag, which replaces the spring, that allows you to adjust to changes in the weight of the car and get no shaking. Another property of an air spring is a change in size, which, if directed in the right direction, changes the ground clearance of the car.

But just in theory. In practice, the following problems arise:

The bag must be strong enough to support not just the weight of the car, but the weight of the car accelerated as it moves up and down. The values are quite large and, accordingly, elastic elements must be designed with a large margin. Hence the higher cost compared to springs.
How to pump and pump out air. This should be done quickly and, if everything is clear with pumping out - the valve is opened, the air “runs out”, and the larger the hole, the faster it comes out, then with the intake everything is somewhat more complicated. It is clear that a compressor is needed. But supplementing the car with a powerful compressor is the wrong option. A powerful compressor, the performance of which is sufficient to solve the task at hand, will consume an unreasonably large amount of energy and take up a huge amount of space. And this is where receivers come to the rescue. A receiver is a metal cylinder into which air at high pressure is pumped with an ordinary small compressor. And when it is necessary to “inflate” the air bag, all the air from the receiver is “spitted out” in a matter of seconds, supplying the required volume. However, usually such fast operation is not required and the flow rate is limited by the cross-section of the inlet opening and an automatic valve-regulator. That is, simply replacing the “pieces of hardware” with “rubber bands” will not work - you still need to purchase additional equipment.
Depending on the purpose, it is necessary that the pneumatic element, when inflated, either maintains its dimensions (or does not increase them much), or increases in height. That is, you need to choose the right air springs to suit your needs.
Installation of air suspension elements in a car. If a car is initially created for the use of air suspension, then, of course, space is provided for all components. And if we are talking about alteration, then we need to find a way to place springs, a compressor, a receiver, as well as lay air lines and power supplies, provide and install control elements - pneumatic valves, relays, pressure gauges, switches. The task is not simple, but it can be solved. That is, you will have to spend money and/or time on installing additional equipment.

What does it consist of?

Air suspension can be installed on one axle or on each axle, and the wheels on the axle can be controlled either independently or independently.

The simplest air suspension installation scheme is used when installing the air suspension on one axle according to a dependent scheme. It consists of a compressor, a receiver, an air flow separator, air cylinders (one for each wheel), air lines, a pressure gauge, a three-position switch (off, inflation, deflation) and a valve that prevents air from escaping from the air bags.

A more complex scheme also includes a relay for automatic control of pressure in the system or each bag; the number of pressure gauges, compressors with receivers, sensors, and controls increases. Microprocessor control units are introduced into very complex circuits, allowing the suspension stiffness to be adjusted without or with minimal driver participation.

On practice

An example of a separate air suspension installed on each wheel are two projects recently shown at the Moscow Tuning Show 2014 exhibition. The two companies showed how different the implementation of the same task can be based on the same main components: a compressor and a receiver.

The Tany company, owner of the Berkut trademark, announced a competition for the best project for installing air suspension based on its products: two Berkut PRO24 compressors and two Berkut AT-08 receivers with a volume of 2 gallons (7.6 l) each.

The special series of Berkut Professional compressors includes two compressors, Berkut Pro 20 and Berkut Pro 24, two receivers Berkut AT-08 and Berkut AT-10, as well as connection kits.

The Berkut Pro 20 compressor is intended exclusively for stationary installation and operation with a receiver, has a capacity of 42 l/min and provides a pressure of up to 10.5 atm. Work cycle 33%: 15 minutes working, 30 minutes resting.

The Berkut Pro 24 compressor is the most powerful model in the Berkut compressor line. Its productivity is 47 l/min, and the maximum developed pressure is 10.5 atm. The duty cycle is 100%, meaning the compressor can operate continuously.

Both models are resistant to temperature extremes, protected from overheating and equipped with a metal braided air hose that can withstand high pressure. The protection class against water and dust is IP67, which allows devices to safely withstand short-term immersion in water to a depth of 1.5 m. Particular attention is paid to the reliability of Berkut Pro series compressors. It uses a piston compressor that does not require lubrication, a powerful heat sink, and a new electric motor design that provides increased efficiency. To ensure the possibility of working underwater, the kit includes a special air duct to accommodate the air filter.

Receivers Berkut AT-08 and Berkut AT-10 have, respectively, a volume of 2 Ga (7.6 l) and 2.5 Ga (10.5 l). Both air storage tanks are designed for a working pressure of 10.5 atm and can be used in any place, including the engine compartment or a niche under the underbody. The inside of the receivers is treated with a special anti-corrosion compound that prevents condensation from damaging the tank walls.

Berkut installation kits allow you to assemble an on-board pneumatic system and are divided into three types. Berkut TG-53 is an entry-level kit that includes 6 positions and allows you to connect one pneumatic device. Berkut TG-55/56/57 is a medium-sized kit that provides installation of an extensive system, with a limiting relay and a pressure gauge. The differences between these three modifications are in the limiter relays, which provide different pressure values at which the compressor turns on/off. And the most complete kit, Berkut TG-59, which allows you to install a multi-tasking pneumatic system with separate control of devices.

At the initial stage, two teams were selected, which showed what could come out of a seemingly purely technical task. Recast chose a VW Tiguan as a donor vehicle and used AirLift airbags and Accuair e-Level controls as components. The LowLaboratory team, when installing the pneumatic system in Toyota Rumion, also chose AirLift pneumatic elements, and, on the contrary, did everything else with their own hands.

The result was completely different in design, although in fact both cars received the same capabilities: raising and lowering each wheel independently.

Both teams installed working elements in the trunks of cars and provided LED lighting.

In both cases, control is carried out from a wired remote control, which is not fixed and can be used by both the driver and one of the passengers.

What was done:

Air suspension installation at LowLaboratory studio

Almost all parts, including fittings and distributors, were made by hand. Also, a podium for compressors and receivers and a decorative cover were made by hand, under which the red LED lighting is hidden.

The heart of the pneumatic system, two Berkut PRO24 compressors, have been cleaned of paint, polished to a shine and complemented with custom air intake caps. The receivers are covered with red glossy paint. All this was fit into a triangle, the center of which is the valve block with the original cover.

Control - a wired unit with four rocker switches, one for each wheel, made independently.

The studio's masters decided to play with leather. It is everywhere: the housings of compressors and receivers, as well as the internal walls of the “pneumatic compartment” are covered with blue and beige material, the top cover is wrapped in black leather. There is glass embedded in the lid with LED backlighting, forming a beautiful pattern. As a result, the trunk, despite the part of the pneumatic system installed in it, namely Berkut PRO 24 compressors and Berkut receivers, can be used for its intended purpose, that is, the functionality of the compartment is preserved.

Control - e-Level push-button remote control with independent influence on each wheel.

In the installation solution from Recast, the pneumatic system is covered with a lid with LED lighting. It should be noted that the studio managed to position the system and preserve the useful volume of the trunk.

The color scheme of the installation is black-beige-blue leather and steel.

Equipment used to create air suspension

Berkut PRO-20 - professional compressor

Professional compressor BERKUT PRO-20 - designed for stationary installation and mandatory operation in conjunction with a receiver (reservoir for compressed air). All PRO series models are equipped with a special high-pressure steel braided hose, a check valve and thermal protection that turns off the device if it overheats. The device is resistant to temperature changes and is also water- and dust-proof. This compressor can be installed in the engine compartment to perform professional tasks: controlling the air signal and air suspension, as well as installing air locking center differentials. Functional features: - Piston type compressor that does not require lubrication - Piston chamber with increased heat dissipation - Air valves made of durable stainless steel - Working cylinder made of aluminum alloy - New type electric motor with increased efficiency - High pressure air hose in steel braid - Air line check valve - Automatic overheat protection system - Dust-proof and water-resistant design - Air filter with duct for remote placement - Set of necessary installation accessories and fasteners

Berkut PRO-24 - professional compressor

Compressor for stationary installation BERKUT PRO-24 is the most powerful and high-tech model in the BERKUT PROFESSIONAL professional line. This compressor can work in tandem with a receiver (a reservoir for compressed air) continuously - the duty cycle of the device is 100%. All models of BERKUT PRO series compressors are resistant to temperature changes and are also characterized by a water- and dust-proof design. The BERKUT PRO-24 model has a protection class of IP 67 - which means short-term immersion in water up to 1.5 meters. For this purpose, the compressor kit includes a special air duct for remote placement of the air filter. Based on this device, you can build the most complex and multi-tasking on-board pneumatic system. Pneumatic signals, air suspension, as well as the installation of air locks - everything can be done by the top model BERKUT PRO-24. Functional features: - Piston-type compressor that does not require lubrication - Piston chamber with increased heat dissipation - Air valves made of durable stainless steel - Aluminum alloy working cylinder - New type electric motor with increased efficiency - Steel braided high pressure air hose - Air line check valve - Automatic overheating protection system - Dustproof and waterproof design - Air filter with air duct for remote control placement - Set of necessary installation accessories and fasteners

BERKUT AT-08 (2 GA) - receiver

Receivers are used to accumulate and store compressed air, as well as to equalize pressure in the pneumatic system. The BERKUT AT-08 receiver is a compact reservoir for compressed air, designed for operating pressure up to 150 PSI (10.5 Atm). If you have little space in the trunk or you don’t want to sacrifice free space - this receiver is for you! The cylinder is equipped with six installation holes, and the inside is treated with a special anti-corrosion coating. Any installation and operation of the device is allowed, even in the most aggressive environments (under the bottom or in the engine compartment).

BERKUT AT-10 (2.5 GA) - receiver

The compressor accumulates a volume of compressed air in a receiver (air tank) - this compensates for the variable flow of compressed air in the line, thus reducing the number of cycles of turning the compressor on and off. The receiver BERKUT AT-10 is the most popular model with a volume of about 10 liters. This receiver is designed for operating pressures up to 200 PSI (14 Atm) and is equipped with six mounting holes. The internal coating of BERKUT receivers is treated with a special anti-rust compound, and the outside of the receivers is powder coated in Deep Gray. Any installation and operation of the BERKUT receiver is allowed, even in the most aggressive environments (under the bottom or in the engine compartment).

BERKUT TG-53 - installation kit for equipping the receiver

BERKUT TG-53 is a complete installation kit for equipping a receiver (compressed air tank). The kit includes various installation components and fittings necessary to install the pneumatic system.

BERKUT TG-55/56/57 - installation kit for equipping the receiver

This complete installation kit is suitable for a motorist who is ready to organize and install an entire pneumatic system on the basis of his car that can cope with any task. The kit is designed for a stationary connection of a car compressor and a receiver - a reservoir capable of accumulating a large amount of compressed air.

The air suspension allows you to adjust the ride height semi-automatically or completely without the use of physical effort. We are talking about replacing springs, springs and torsion bars with pneumatic cylinders, in which compressed air pumped from the system acts as an elastic element. Despite all the advantages of this element, a do-it-yourself air suspension can only be created if you have basic car repair skills. The process is fraught with certain difficulties and a beginner clearly cannot cope with it.

Air suspension device

The design of each air suspension consists of a receiver, a control unit, an air distribution system and a compressor. To improve driver comfort, the suspensions can be automatically or manually controlled.

Automatic air suspension involves independently selecting the ride height electronically, taking into account factors such as acceleration, speed, and inclination. The focus in this case is on high aerodynamic performance. The center of gravity is reduced, so the car's controllability is significantly increased.
Manual control requires the driver's initiative when choosing the height of the ground clearance relative to the road. Manual adjustment is also possible in relation to the stiffness of the suspension if its design involves the presence of shock absorber pneumatic struts.

Modifications

There are three modifications of air suspension:

Single-circuit options are designed for installation on one axle and provide the same pressure in both cushions on it, since the compressor and cylinders are located on the same circuit.
Double-circuit modifications are also installed on one axle, but in essence these are two single-circuit suspensions, thanks to which it is possible to adjust the height of the front and rear of the car relative to each other. The main disadvantage is the roll of the car, since there is a pressure difference between the two wheels that run along the outer radius.
Four-circuit options are considered the best because they use four separate valves for each wheel, pressure sensors and a microcomputer for control. Consequently, the problem with roll is eliminated in this case, since the pillow steadily holds the required pressure.

Advantages and disadvantages of air suspension

Due to the positive properties of air suspension, there is a tendency to install it on both trailers and trucks, as well as passenger cars. The advantages of tuning a car with air suspension are represented by the following possibilities:

Ride height control. This improves handling under all road conditions. In this case, the springs do not need to be changed to softer and longer ones or shorter and harder ones (read also about).
Under heavy loads, sagging can be avoided, as the height and stiffness adjustments ensure consistent ride quality.
Handling is significantly improved, and the air suspension compensates for the difference between hard and soft springs by adjusting the pressure.
When driving on uneven roads, body vibrations are smoothed out.
It is possible to install air suspension on any car.

The advantages are significant and there are many of them, however, it is worth knowing about the disadvantages:

Poor resistance to road agents and frost, which significantly reduce the service life of the suspension.
The level of maintainability tends to zero, so failure of one of the elements requires a complete replacement of the suspension.
The cost is much higher compared to traditional shock absorbers.

Air suspension assembly

Since a do-it-yourself pneumatic device is only a subtype, installation is possible on an existing car suspension. The essence of the installation is to replace elastic elements with pneumatic cylinders, therefore, such a modernization scheme can be carried out on any machine. All that remains is to find out how to make an air suspension with your own hands and how to install it.

Necessary tools, materials and equipment

The equipment in this case is standard and every driver has it if he periodically encounters the need for repairs:

sealant;
hammer;
metal brush;
Bulgarian.

Do-it-yourself air suspension consists of the following components:

a set of racks, even if the ones currently installed are reliable;
receiver (you can make it for air suspension with your own hands and not buy it);
air suspension cushions;
compressor;
several different fittings and PVC pipes with a diameter of 6 and 8 mm;
two pairs of solenoid valves;
Any oil and moisture separator will do;
pressure gauge;
Control block.

Front suspension assembly

It is worth considering separately the technology for installing the rear and front suspension, since in the case of the latter the scheme is more complex.

Knock the cap off the stand and clean off the paint layer using an angle grinder.
Press the adapter onto the post and add spacers underneath to increase the softness.
Select small diameter fittings or tubing and place them near the air holes in the adapter.
Install the air spring onto the strut. The height of the bump stop should be calculated in advance, otherwise the spring may fail after the first strong impact on the road.
Use caulk and a copper press washer to seal the connection.
Secure the support bearing to the strut so that the rod does not rotate inside the shock absorber when the steering wheel is turned.
Connect the air tube to the pillow socket.
Now you can install the finished structure.

The step-by-step procedure for assembling the rear suspension is as follows:

Trim the spring cup a little and remove the paint coating.
To the end of the rack rod it is necessary to cut a thread for pneumatics.
To seal, install a press washer and then put the air spring on the rod.
To achieve particularly smooth movement, you can not install a bump stop, which will result in a strong lowering of the rear of the car.
Press the air spring to the end of the shock absorber.
Apply air supply.

Installing air suspension on a car

Before installing the air suspension yourself, remove the struts from the car. A beginner's skills will be enough in this case - just lift the car with a jack and follow the step-by-step process.

Use existing holes to install the stand or make new ones if necessary.
Remove the rubber bands and stretch the tubes to ensure air supply; then they must be secured in relation to the body using clamps.
Attach the receiver to a special bracket near the gas tank.
Lead the tubes from the airbags along the steering rods and lead them into the engine compartment. Make the wiring in two directions - to the receiver valve and the relief valve.
Connect the pneumatics to the control unit toggle switches.

Functionality check

Be sure to check the system's functionality. After increasing the pressure to 8 atmospheres, check for leaks in the system by ear; there should be no hissing. Next, set the pressure in the system to 6 atmospheres for the rear suspensions and to 8 for the front ones. Do not rush when pumping air, otherwise there is a chance that the compressor will overfill the system. At the final stage, adjust the wheel alignment.

Suspension control

A control unit with 8 buttons is responsible for controlling the air suspension. Each button is responsible for a specific strut or shock absorbers in the complex. To receive data from each airbag, be sure to install the controller in the car interior. Based on the road situation, you can reduce or increase the air pressure in the airbag to reduce or, accordingly, increase ground clearance.