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Honda Accord: Adjustable Air-Ride Suspension Andrew Totolos installs an adjustable suspension system that will raise (and lower) the show-car profile of a Honda Accord. From "Tricked Out" episode DTRK-410

(Continued from page 3)

Andrew with the finished wiring and board

Phase 3: Construct and Install Base Plate

With the front and rear air struts installed, Andrew now constructs a base plate onto which he will mount the components for the suspension system. With the help of a friend, Andrew places the finished base plate in the trunk of the project car.

Tools and materials:

standard shop tools
drill with bits
medium-density fiberboard (MDF)
carpet
adhesive
split loom
marker

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	The wires from the brain center are secured with zip ties.
	Figure B
	Figure C

Base Mounting Plate and Wiring

Andrew decides to mount the base plate over the tire well, and he will try to hide the wires and hoses. That' s why he' s chosen to have the air compressors located closely to the tanks.

Tip: The components should be properly organized before being installed on the base plate. Keep in mind how everything will need to be connected and lay out the design in a way that simplifies the hookups.

• Andrew runs the compressor hoses down through the MDF and back up the MDF for a sneak attack to connect to the inlet ports on the tank. In order to do this, bend the hose, taking care not to strain the hose at all. Find a comfortable bending spot and go straight down and make the placement mark on the MDF base plate. The wires will be hidden under the solenoids, and Andrew will put the sensors down through the MDF.

• After decideing on a layout, start marking the locations on the base plate for all the components. Also mark where the hoses and wiring will pass through the board.

• Once the marks are made, remove the components and start drilling the holes.

• Use a one-inch-hole saw bit to drill the larger holes for the hoses and wiring to pass through. Switch to a smaller 1/4-inch bit to pre-drill pilot holes that will be used to mount the components (figure B).

• Once all of the holes are drilled out, it' s time to cover the base plate with elastic carpeting that will stretch to fit tightly around odd corners. Use industrial-strength adhesive to stick the carpet to the board. Make sure to apply the adhesive to both the board and the carpet. Allow the adhesive some time to get tacky before attaching the carpet to the board.

• After the glue has had a few minutes to tack up, carefully flip the carpet over and smooth it onto the base plate. It' s easy to tap a deep well socket into the larger holes for a smooth wrap. Use a punch to poke through the rest of the smaller holes.

• On the backside of the board, hammer a few T-nuts into the mounting holes.

• It's now time to mount the compressors on the base plate (figure C). Tuck the wiring down through the board, and run the compressor air lines under the board to their proper locations.
  

  Andrew secures the wiring.

• Mount the remainder of the components to the board, hooking them up and running the wiring and hoses as you go.

• The components have been tightened down. There are a few more things to install at the workbench. Add a couple of 90-degree elbows to the output fittings on the tanks.

• Attach one end of the hose to the input on the solenoid block, cut the hose to length, and hook it up to the tank.

• Repeat the process on the other side.

• Next, it' s time to mount the electronics. Andrew decides to mount them underneath the baseboard and then flip the base plate over. Andrew calls in a helper to give him a hand to turn the base plate over.
  

  	Figure D
  	Solenoids center

• Before they flip it over, Andrew and his helper wrap extra carpet over the tanks to protect the custom finish.

• Attach the ground wires to a common terminal block (figure D), and mount the brain box to the underside of the board along with a couple of relays that attach to the exposed mounting screws with extra nuts.

• Following the manufacturer' s instructions, connect all of the wiring, and straighten out the hoses and wiring in the trunk.

• Connect the power harness to the relays, and wrap it all up in split loom for protection.

• With the assistance of a helper, prop the assembly up in the trunk in order to hook up the hoses that run to the struts and make all of the electrical connections.

• Slide the board into the trunk, connect the system to the battery, and tuck the carpet around the sides of the trunk.

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