Front suspension & bearings are new - Sharp knock on bumps

[WBPDX]

Car is a 1979 Spider. Sharp knock is only on bumps, and definitely passenger side front. The knock is not felt in the steering.

I replaced all the bushings in the control arms, installed new ball joints upper and lower, tie rods (complete,) drag link, and wheel bearings and races. I also installed new shocks and cut the springs one coil. Also, new tires and new brake calipers. Everything has been checked for tightness\looseness 2-3 times.

I got an alignment.

After the work, the car drove great, but I had some front end noises. Then, I looked and saw that the passenger spring had tipped in the upper mount, and the spring was no longer seated properly. I fixed this, and now both springs\mounts seem correct, but the knock is still there. I then double checked the wheel bearings, and they are tight. All of the nuts seem torqued correctly to the best of my ability. The tie rods seem seated. I will mention, my only idea left is that the lower ball joint might not be totally seated, but I think it is a long shot...

I am running out of ideas and things to check - I don't expect anyone to tell me the solution, just help with ideas of things I may have missed.

Again, the knock is not felt in the steering, it is just a loud hollow sounding "wunk" that is definitely in the front, and definitely on the passenger side. It occurs only on bumps in the road; a man hole cover with a dip of 1/2"+, a pot hole, a speed bump, etc.

As of right now, this is really the only major reason I am not using the car regularly, and summer is running out FAST - Please, any help would be appreciated!

[So Cal Mark]

can you bounce the car and duplicate the noise?

[FiatMac]

I had a similar noise once. It turned out to be a missing rubber sway bar bushing at the connection to the passenger side lower control arm. The knocking noise was the sway bar end hitting the bushing mount.

[WBPDX]

Sway bar end bushings are new too, and everything looks good with the sway bar.

I *can* reproduce the sound by bouncing hard on it. Sounds like I need to find a friend to bounce it while I watch\listen under the car.

Any more ideas?

[DocGraphics]

Check to make sure both ends of you shocks are tight (guessing)

[WBPDX]

Check to make sure both ends of you shocks are tight (guessing)

First thing I thought of, because that is distinctly what the sound sort of sounds like - All is well.

[124ADDHE]

What about the crossmember bolts? Idler bolts? engine mounts? ignition coil clamp?

[WBPDX]

Crossmember Bolts - Checked when everything was apart
Idler bolts - Also checked on the passenger side while everything was apart
Engine mounts - Are brand new, and are also tight. Also not sure I could reproduce this one just by pushing down.

Now I just gotta find someone to push down on it while I crawl under... Nobody is around when you need them!

[narfire]

My guess was going to be the sway bar ends. The nuts on mine kept backing off,not much but enough to thunk. Lock-tight and tightened...three years and no problems any more.
Chris

[WBPDX]

The bolts on the sway bar end did loosen up before, but I tightened them again. Maybe I need to check them again.

Last night I didn't really get anywhere. I couldn't find anyone to help! Maybe this weekend I guess...

[majicwrench]

With the car up on ramps you should be able to crawl underneath and push/pull up and down and create the noise. I have a one-man auto repair shop and do it all the time. Also, you should be able to feel that noise as well as hear it, and sometimes it is easier to isolate the issue by using fingers hands to "feel" the noise.
Keith

[ace124]

Check you exhaust down pipes are not too close to the crossmember. If the engine mounts are softish or a bit saggy or wrong height, then it will hit.

[WBPDX]

They aren't saggy, they are brand new. Lots of clearance.

Tried by myself, I can't generate quite enough force while lying down on the ground to make the knocking sound. Damn close, but not quite.

[bark]

If you have the plastic wheel well shields in place, check to make sure the lower control arm clears the edge of the shield. Makes a hell of a scary sound if it's barely " plucking" as the control arm travels past the edge. Ask me how I know! B-

[WBPDX]

It actually was the upper shock mount despite the fact that it was completely tight. I am still not totally sure how or why. I could not get it tight, so I took the shock all the way out, didn't change a darn thing, and put it back, this time with a lock washer to maybe put a little extra force on the rubber bushings. Knock is gone, even though I swear it is just as tight, and aligned in the exact same way.

I'm thinking the shock may have been bent\damaged when the spring slipped part way off it's perch at one point. If the knock ever comes back, I'll replace the shock.

What is funny about fixing these terrible noises, as soon as one noise is gone, you just notice other noises more. Now that the front end is quiet and smooth, it really stands out out bad the rear end is!!!