Finally got the shocks built, and man these are tasty. Seriously big, and superbly machined. There are no less than 22 components per shock!
The components for the front shocks and o-rings/ washers for all four.
Please note these are obviously the shocks from the first generation 808 and not the '09 spec one.
The OD of the springs is just shy of an inch!
The six hole pitsons.
The washers are definitely different from those included in previous models. They look to be machined, not stamped, and feel thicker than before. They are only needed underneath the the piston.
The ingredients to make one shock (minus the spring!).
The end assembly.
Clever machining of the end cap means the o-rings are held securely but the felt pad isn't squashed at all.
I cut some round pieces of foam to sit in the cap underneath the bladder.
Not that important, but just thought I'd show how I catch the excess oil when bleeding shocks. Means you can hold the shock upright but no oil drips down the side of the shock body!
All four shocks filled and bled.
I used a cutting tool on a Dremel to cut a little groove in the centre of the adjusting nut. I did this after I had assembled the shocks and made sure it was screwed all the way on to the body. It just means you can easily make equal adjustments left and right.
Cleverly one turn on the adjusting nut = 1mm, so 11 turns out equals 11mm!
The inserts for the shock cap are made from a piece of machined steel, and two moulded plastic inserts. They hold together very well and the assembly doesn't fall apart when the shocks are removed from the towers.
Notice the zinc plated left hand threaded screw on the left (in the picture) lower arm. This stops the right front and left rear screw from backing out.
All four shocks installed in their default holes. For the time being I've gone with the stock setup for oils, so thought I'd try out the factory settings for the shock positions. The recommended droop settings are WAY off, so I've set my droop so the front shocks are 104mm and rears are 114mm from centre to centre on the mounting points.
All in all the shocks are hands-down the nicest shocks I've built. Not sure how you US guys will feel about still using the felt washer, but I've never had a problem with dirt entering my XT8 shocks here in the UK, so can't complain. And no more split shock boots!