Abstract: A piston and piston rod subassembly for use with a hydraulic damper is disclosed. The piston is formed from a substantially flat blank having a pattern of bendable tabs provided along a first edge. A bendable skirt is provided along a second edge of the blank. After the blank is formed into a cylindrical body, the tabs are crimped onto a flanged end of a piston rod. A valve assembly can be retained in the cylindrical body by crimping the skirt over the valve assembly.

Abstract: A piston and piston rod subassembly for use with a hydraulic damper is disclosed. The piston is formed from a substantially flat blank having a pattern of bendable tabs provided along a first edge. A bendable skirt is provided along a second edge of the blank. After the blank is formed into a cylindrical body, the tabs are crimped onto a flanged end of a piston rod. A valve assembly can be retained in the cylindrical body by crimping the skirt over the valve assembly.

Abstract: A compression valve assembly includes a valve cage having a stem at a first end and an annular skirt at a second end. The skirt is provided with a slidable surface. A relief valve is adapted for selectively blocking fluid flow through the valve cage. A cup includes an annular rim and a base. The rim is provided with a slidable surface. A spring biased agaist the relief valve is selectively compressed as the cup rim is slidably received over the skirt by a measured axial load provided by a preloading means. The cup is secured to the valve cage and the axial load is removed.

Abstract: A load cell exerts a force on a loose spring cage of a rebound spring to displace the cage and hold it in position on the piston of a hydraulic damper unit until it is welded in position. This preloads the rebound spring to close tolerance so that rebound valve operation is constant regardless of variation in spring sizes, rates and stack up heights of valve components.

Abstract: A modular piston having a high tensile strength piston and rod connection produced without lubrication, weld splatter or other contaminants. The method produces an optimized joint from strength, concentricity and cleanliness standpoints. The parts are centered and connected in the same operation. With this connection an elastomeric bumper and bumper containment plate are retained in position for a complete assembly.