Installing Aluminum Bushings

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This video illustrates multiple techniques that you can use as a combo attack to help you conquer this interference fit! There may be plenty more great tricks in the comments because astute gear heads know they're always welcome here! I have an extremely capable and creative audience! Thank you all for tuning in!

The GSX's subframe has been installed, but not without a modification that required extensive work and close attention to detail. Without the powder coating, all of the same preparations for the part to receive the bushings is still required.

The process of installing the bushings isn't by itself a difficult one, but does require appropriate attention to detail in advance of doing so.

I did this job without measuring or modifying the bushings because most other people probably won't. The bushings I selected were perfectly sized, and they fit correctly. That's a true testament to their quality, and Volk Metalcraft's attention to detail. I did not have to modify them for them to fit.

The process of pressing them in is difficult because of the size and shape of the part they're being pressed into. The tools that provide enough tonnage to do the work do not accommodate a 2g subframe very well at all. It's extremely awkward. Any single small error in 1) your rigging on the press, or 2) with the support of the rest of the subframe that extends outside of the press, or 3) not immediately recognizing a misalignment during the process, or 4) a part of the subframe coming in contact with the framework of the press while it's under load, or 5) overloading the part/press... all of this is capable of severely damaging your subframe. So 6) do all of the above.

None of this takes into account the condition of, or the potential defects that might be in your subframe like mine did have. If you get that bushing installation right, now you have to do it correctly 5 more times to complete this job. All it takes is one mistake. So be extremely careful.

Pressing in subframe bushings by yourself only makes it more difficult, but if you're using a stand like I showed, ensure that its height doesn't allow the press rigging to become mis-aligned. All of the parts between the press and the anvil must be perfectly level as the bushing is driven in. An extra set of hands and eyes would definitely have been good for me on the press, but I regret nothing. I have a great support system; in my shop, within my IRL circles and the brave warriors who support me on Patreon who know people love seeing new ways to get themselves out of a similar jam.

Now that this part is complete, the rest of this assembly is easy. Be on the lookout for the rest of the GSX suspension and steering assembly coming soon!