Saturday I installed THR bushings with new Lemforder arms. On my test drives I heard a sound that I called a clunk but is likely what you're calling a pop. I verified again that everything was still torqued correctly, no sway bar bushings had torn off, etc.
Sunday evening I sent an email to THR asking for advice. Monday morning Jon called me from THR. He says the extra thickness of the paint causes the bushing to grip the arm, then the bushing pivots in the bracket. The clunk/pop sound is from that pivoting motion. The correction he suggests is to remove the paint, whether with sandpaper, a wire brush, a wire brush in my drill, or whatever. He says he's going to post that as a tech note on the THR website.
I didn't have a chance tonight to get under the car, but his explanation is plausible so I'll try his suggestion as soon as I get a chance.
Regarding harshness: I drive older cars for their visceral connection, not a new isolation cocoon E90 or E60 or E46. I use my cars as daily commuters, also racetrack and autocross. I don't mind a bit of road noise and I prefer all the road feel I can get. I honestly can't discern any increase in harshness in these THR CABs over the stock rubber, but I do enjoy the added bit of tactile feedback in my steering.
Sunday evening I sent an email to THR asking for advice. Monday morning Jon called me from THR. He says the extra thickness of the paint causes the bushing to grip the arm, then the bushing pivots in the bracket. The clunk/pop sound is from that pivoting motion. The correction he suggests is to remove the paint, whether with sandpaper, a wire brush, a wire brush in my drill, or whatever. He says he's going to post that as a tech note on the THR website.
I didn't have a chance tonight to get under the car, but his explanation is plausible so I'll try his suggestion as soon as I get a chance.
Regarding harshness: I drive older cars for their visceral connection, not a new isolation cocoon E90 or E60 or E46. I use my cars as daily commuters, also racetrack and autocross. I don't mind a bit of road noise and I prefer all the road feel I can get. I honestly can't discern any increase in harshness in these THR CABs over the stock rubber, but I do enjoy the added bit of tactile feedback in my steering.
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