help with bodge needed!

[Adam32]

I am replacing the front upper suspension arm on a 1998 Ssangyong Korando due to failure. The problem is the rubber bump stop (part number 4448103000) that sits under the arm is broken. The bump stop has a moulded plug on the bottom that has snapped off (see red circle in photo). This moulded plug pushes into a mounting hole (hole approx 10mm diameter) to secure the bump stop (see photo of mounting point and arrow pointing to it). The problem is I have contacted the dealer and they don't have any of these bump stops in the UK and have given me a lead time of about 6 weeks. I desperately need the vehicle back on the road, as I will be moving house next week!

Not sure if there is anything from other vehicles that may work that I can order quickly? The approximate remeasurements of the bump stop are 44mm wide and 25mm thick. Failing that, any ideas of bodges that may work? I wonder if I could drive a screw into the bottom of the stop or something? Any ideas would be much appreciated as I am really desperate to get things back together.

Below are some photos:

[Captain Answer]

Look fairly similar to these, see if a motor factors near you has them and measure up with some calipers

https://www.ebay.co.uk/itm/151752978166?hash=item2...

[Adam32]

Captain Answer said:

Look fairly similar to these, see if a motor factors near you has them and measure up with some calipers

https://www.ebay.co.uk/itm/151752978166?hash=item2...

They look a different profile, being quite pointy at the top. The one I have is a much flatter profile. Exact measurement is difficult as it has worn /degraded over the years, but upon measuring I get approximately 44mm wide and 25mm thick. Local motor factors does not have any in stock.

[kiethton]

although it'd likely be well-used as a temporary fix there are a few on ebay listed as breaking - you'd likely get that part for penny's if you went and got it/if there was one local enough

[Captain Answer]

Adam32 said:

Captain Answer said:

Look fairly similar to these, see if a motor factors near you has them and measure up with some calipers

https://www.ebay.co.uk/itm/151752978166?hash=item2...

They look a different profile, being quite pointy at the top. The one I have is a much flatter profile. Exact measurement is difficult as it has worn /degraded over the years, but upon measuring I get approximately 44mm wide and 25mm thick. Local motor factors does not have any in stock.

You won't find the exact same shape and size unless you get the real ones in there if the profile is a bit pointier but longer them mr angle grinder can help with that

[InitialDave]

Just run it without the bump stop until the new one arrives.

[Jazoli]

For a quick fix drill a hole through the centre of the bump stop then drill a larger hole for 50% depth, fit a long bolt and attach it to the chassis, tighten the bolt so that its head is pulled into the bump stop to 50% depth, fixed, probably forever if you forget about it.

Apologies for the quick paint job

Edited by Jazoli on Tuesday 18th May 11:52

[GreenV8S]

I'm not familiar with that car, but from the position I guess that's a droop stop not a bump stop. It should hardly ever be used unless you're in the habit of launching off speed bumps. If that was me, I'd be happy to ZIP tie it to that bracket and drive like that for a few days. You aren't planning on driving off road, are you?

[Adam32]

Jazoli said:

For a quick fix drill a hole through the centre of the bump stop then drill a larger hole for 50% depth, fit a long bolt and attach it to the chassis, tighten the bolt so that its head is pulled into the bump stop to 50% depth, fixed, probably forever if you forget about it.

That seems a good idea, but how would you drill the rubber? I have not had much success drilling rubber in the past. I thought about maybe freezing the rubber in a block of ice, or maybe heating up an old drill with a blow torch and more burning through?

As for the bolt, I guess you would want something not to wide to avoid splitting the rubber? I was thinking something like an M5? Just measured a few cap bolts with a small allen head and they measure:

M4 has a head diameter of 7mm
M5 has a head diameter of 8.5mm
M6 has a head diameter of 10mm

So I guess if I drilled a 5mm and an 8.5mm hole, the head of an M5 would pull in nicely.

Edited by Adam32 on Tuesday 18th May 13:01

Edited by Adam32 on Tuesday 18th May 13:06

[E-bmw]

FOB self-tapper, washer, contact adhesive, looks like you could get it from underneath.

[zsdom]

Cant you make a hole through the middle & cable tie it in place?

[Pastie Bloater]

InitialDave said:

Just run it without the bump stop until the new one arrives.

This, plenty of these fall off without any ill effect, just replace when possible.
Don't start bodging things you'll be tempted to leave it