Each student (or team) receives a donor vehicle or detailed case study:
“This vehicle will be used for [specific use case — weekend desert touring / heavy expedition / fast dune running]. It currently has [current setup]. The owner’s budget is [amount]. Diagnose the current condition. Specify a complete suspension package. Justify every choice.”
Deliverables:
1. Full inspection report with photos/measurements
2. Load analysis (current weight distribution, intended loaded weight)
3. Complete parts specification with part numbers and pricing
4. Geometry analysis (what the build changes: alignment, driveshaft, CV angles)
5. Build priority order with reasoning
6. Predicted ride frequency and damping ratio at empty and loaded weight
7. Maintenance schedule for the completed build
The framework for planning any desert 4×4 build. Each step assumes you’ve completed the ones above it.
| # | Upgrade | Why This Order |
|---|---|---|
| 1 | Matched springs + monotube shocks | Foundation. Without correct rate and decent damping, nothing works. |
| 2 | Geometry correction | Lets you align properly. Without: tyre wear, CV stress, steering problems. |
| 3 | Tyres + pressure management | Contact patch. Right tyre at right pressure outperforms every bolt-on. |
| 4 | Remote reservoir shocks | Desert capability begins. More oil = sustained performance at speed. |
| 5 | Hydraulic bump stops | Unlocks last inches of travel safely. The “wow” upgrade. |
| 6 | HD steering components | Must match tyre size and intensity. Failure is catastrophic. |
| 7 | Brakes, skids, breathers, gussets | The “keep it alive” tier. |
| 8 | Long travel, bypass, beadlocks | Performance tier. Only when everything below is sorted. |
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Buying Stage 3 shocks and bolting them to a vehicle with factory UCAs, worn ball joints, and no alignment correction. Suspension is a system. Build the foundation first.
| Symptom | Likely Cause | Fix |
|---|---|---|
| Solid axle unstable after lift | Caster, panhard, arm angles | Correct all three — 90% of problems |
| IFS problems after lift | UCA range, CV angles, bump steer | Aftermarket UCAs solve most |
| Shocks fade after 20 min | Oil overheating | Bigger bore, reservoir, or both |
| Harsh bottoming | No hydraulic bump stops | Install hydraulic bumps |
| Excessive bouncing | Rebound too fast | Slow rebound adjuster |
| Packing down | Rebound too slow | Speed up rebound or add preload |
| CV clicking | Steep angle; worn joints; torn boot | Correct geometry, replace, inspect |
| Highway wander | Low caster; worn joints; panhard | Fix geometry before adding stabilizer |
| Wheel hop | Axle wrap | Traction bar or correct arm angles |
| Death wobble | Resonance cascade | Fix ALL worn components — no single fix |
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| Component | Weight | Description |
|---|---|---|
| Weekly Quizzes | 15% | 10 MCQs per quiz on that week’s content |
| Lab Reports | 15% | Measurements, photos, analysis from each lab |
| Assignments | 20% | Calculations, specifications, written analysis |
| Midterm Exam | 15% | Theory: physics, architectures, components |
| Capstone Project | 20% | Full vehicle diagnosis and build specification |
| Final Exam | 15% | Comprehensive: theory + application + diagnostics |
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85%+ overall for course certification.