Installing Longer BumpStops

By Moe

December 19, 2001



This article documents an install of longer bumpstops on a ’96 Discovery.  This is a 15-20minute job and is designed to address some of the issues that come with installing taller tires or longer shocks.  Already running with 235/85 tires, I had lengthened my OME shocks after purchasing Expeditionware Spring Retainers.  I roughly followed the instructions for lengthening shocks as detailed in the article at http://www.expeditionexchange.com/drop. By lengthening the shocks, one regains some drop but with the added potential problem of the shock bottoming out when the wheel is stuffed into the wheel well.  To address any further problems that could occur with the shocks acting as bumpstops, I installed longer bumpstops made by Daystar.

Tools used:

Material used:

·         KUO9014 Daystar Bumpstops.

Daystar catalog can be found at their website.

http://www.daystarweb.com

I purchased the bumpstops from a dealer in Oregon.  I believe the price was ~ $27

http://www.wheelersoffroad.com

First remove the stock bumpstops from the vehicle, each is held on by two bolts.  Next place the bumpstops in a vice and take an old wood chisel and separate the solid rubber from the metal frame.  Once the rubber is removed, drill a hole in the center of the frame to accommodate the bolt from the new bumpstop. 

Invert the old frame and attach the new bumpstop.  Reinstall bumpstop on vehicle.

I believe the length of the KUO9014 is 3-1/2” and with the inverted plate it comes to around 4”.  Given that the Daystar stop is not solid, the real difference between the stock and new bumpstop is less than it visually appears.  The Daystar bumpstops obviously crush under compression.

First impression is that they are damn ugly but seem to do the job.  Over the summer, only once with a heavy load did the rear tire rub slightly in the wheel well.  The bumpstop is not so big that it prevents good stuffage and could actually offer a little more resistance for my setup.  I am considering fine tuning the bumpstop by packing and sealing up the top slit to make it a tad more solid.  Another option would be to purchase the 4-1/2” bumpstop of the same type.