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Seen one patched up with fibreglass and hopes and prayers before :D
Yeah, that's shot, even if you repaired it it'll crack further around, you can see where it's propagating. That and the casing will have shifted when it went under load so the diff bearings won't be true to each other any more...
Some of that is b****cks really, the rebound and rebound damping curve required *will* change depending on the spring preload. because you change the forces especially near full rebound travel. Changing the handling and chassis behavior too.
Usual case of a little bit of knowledge being a...
You can only use thinner tubing if you get the cage designed certified by somewhere like MIRA as a 3rd party, you're looking at adding a grand to the cost of a one off-cage for that alone.
They're going to need to be printed in polycarb or a fibre-filled ASA/Nylon blend, or just nylon, really, to stand any chance of surviving. 3D printing something that size in decent material isn't cheap. 3D printing is cheap when you consider you don't have to make moulds for prototypes and...
I would suggest switching to a split outer-race bearing to make sure you have very low preload, fill that with a silicone damping grease, and fit a grub screw to the housing so you can just nip it up enough to remove any play that might contribute to the rattling without getting the shift too...
Yes, they're printed Bankrupt - there's actually internal voids/geometery in there that would be pretty much impossible to replicate otherwise.
For everyone else, heating them to help with fitting is fine - use a heatgun or hairdryer is better than water though as you can keep it warm as you...
They can usually trim them in what you want if you're wanting leather/vinyl, etc, but the high sides are probably an issue though, even on their smaller seats.
Has it got to be those two Frayz? I'd suggest having a chat with Motordrive if not, they'll tailor the seat to your body dimensions if you wish, the bases are a bit deeper though with them being aimed at competition only.