Adjustable coilover suspension provides the added ability for fine tuning. With the adjustable coilover suspension, weight distribution, weight transfer, dampening and rebound can be set to meet a variety of motorsports and road conditions. Tanabe adjustable coilover suspensions range from types available for comfort and street performance, to full race models suitable for competitive motorsports. Tanabe is partnered with Kayaba Industry Co. of Japan (KYB), Japan's oldest and most celebrated dampener manufacturer, in the production and engineering of the highest performing, most durable suspensions for a variety of driving applications.
Sustec chassis reinforcement products complement the Tanabe suspension tuning line. When the power output of a vehicle is upgraded, and handling potential is increased with upgraded springs, dampeners, and/or adjustable coilovers, additional stress is placed on a vehicle. As it was not built to carry excessive loads, the chassis will have a tendency to slightly flex more than normal, which can cause slight instability and deficiency in handling. To improve chassis rigidity, front and rear tower bars are available to reduce flexing of the shocks towers. For the undercarriage, Tanabe reinforces the chassis using oval shaft underbraces. Chrome-moly sway bars are also available for many vehicles to finalize the upgrades to the chassis and improve cornering speed and stability.
The function of a spring is to compress and store energy, and then release it and return to its initial state. It is designed to perform this action numerous times without losing its original shape and strength. On automobiles, this function keeps the tires in contact with the road to maintain traction. Additionally, the coil springs support the weight of a car, absorbing shock, and managing weight distribution and transference. Taking these factors into consideration, Tanabe extensively developed spring manufacturing technology to produce the strongest, most reliable and durable spring available. Tanabe springs are one of the strongest springs currently available for automotive use (2100n/m) and are manufactured using some of the most advanced methods and machinery.
Tanabe performance coil springs have an extremely high tensile strength of 2100nm and are manufactured using only cold formed steel. This is the meaning behind the '210' suffix at the end of all Tanabe high performance coil spring lines. The secret of strength and extended durability is in advanced manufacturing process.
Tanabe owns and operates one of the most advanced coil winding machines, the WAFIOS. This machine is the only one of its kind to be owned and operated in Japan, setting Tanabe apart from all other spring manufacturers in the region. Because the newest model WAFIOS utilizes proprietary patented technology, there are a few companies that can use this machinery. Mr. Suteo Tanabe's strong relationship with WAFIOS of Germany and his well known reputation for quality product development and manufacturing helped in the acquisition of this advanced multimillion dollar machine.
In addition to the WAFIOS coil spring machine, Tanabe springs are manufactured using several patent pending processes that cannot be found anywhere in the world!
* Hign tensile wound steel is run through thr WAFIOS cold winding spring machine.
Coil spring winding is the process where the high tensile steel is wound in the spring coiling machine, and the spring takes it's shape and length. Large rolls of high tensile steel are fed into this machine for the winding process. Utilizing advanced WAFIOS machine, cold winding process maintains a very low temperature to wind the spring. Most springs are manufactured using an older hot winding technique, which heats the spring to a very high temperature to soften the material and make it easier to wind. High heat, even for small amounts of time, unfortunately results in a detrimental side effect of causing the internal molecular structure of the steel to expand, which in turn weakens the overall strength. By reducing temperature during the winding process, the internal structure is kept tightly packed, which maintains the steel's strength. Cold winding is the best process for producing a spring with extremely high tensile strengths. Because cold winding does not expose the material to high temperature, an advanced machinery such as WAFIOS is required. Most manufacturers are unable to cold wind their springs because less advanced winding machines would cause the high tensile steel snap if cold winding was attempted.
* The coil springs are placed for cold tempering and the finished tempered springs.
Tempering is a process that hardens and further strengthens the steel. Tempering improves the consistency of the internal structure to eliminate the possibility of weak spots within the spring. The coil springs are processed through this machine, which keeps them at a specific, constant low temperature for an exact amount of time. This process is monitored closely to ensure that temperatures do not vary so all remaining internal resistance at the molecular level is removed, and the spring increases its strength.
* Doble shotpeen machine with processes springs individually, instead of a batch.
Shot peening is a process that shoots various size steel ball bearings against a surface, to cause beneficial unevenness of the surface, which improves tensile strength. Older shot peening processes perform this on one large batch of springs, which greatly reduces actual coverage. This machine is unique as the coil springs are processed individually to ensure maximum and even coverage during the shot peen process. The coil spring is run through two unique shot peen processes, which is a part of the confidential formula for Tanabe's 2100nm of tensile strength. This patent pending process for true individual double shot peening is unique to the Tanabe Shiga factory.
* The machine is the humid grinder, whitch flattens the top and bottoms without crating heat.
For the PRO210 adjustable coilover springs, the top and bottom edges are humid grinded flat, for fitment onto the seats and spring perches. Conventional grinding methods cause excessive friction, resulting in high temperatures which dissipate throughout the spring, reducing overall strength due to heat expansion. The Humid Grinding machine does not produce excessive heat during the grinding process.
* Tanabe load and compress the springs to 100% to eliminate the possibility for sag.
Loading of the spring is a part of the final testing process after production. Loading the spring compresses it to measure the strength and ensures tolerances within the spring's structure. Conventional loading processes ensure only 50-70% load, which causes sag and deformation. This machine allows for 100% spring compression to ensure each spring is fully functional. By loading the spring to the full, the experts at Tanabe assure it is pre-engineered and tested to never sag or deform.
* The specifications, measurements and tolerances are cheked and tested.
Each specification for the spring is measured and tested after production, to ensure the spring rates and lengths are even and consistent for perfect function, quality, and fit. Thanks to commitment to perfection, advanced manufacturing process, and stringent quality assurance, Tanabe has acquired the world quality manufacturing certification, ISO9001.
* On the final stage, the springs are treated with a durable powdercoat finish. The Sustec 210 Series is born!
After production and numerous testing procedures, the springs are powdercoated.
With an extensive experience in developing exhaust systems for race applications in conjunction with feedback from Japan's top race teams, Tanabe exhaust systems feature a lightweight, free-flowing, straight-through design for maximum performance and durability. Constructed entirely of SUS304 stainless steel with the exception of the Ultra Medalion titanium cat-back exhaust system, Tanabe exhausts weigh significantly less than factory installed stock exhaust systems by up to ~ 40%. SUS304 stainless steel construction is lighter, stronger, and resistant to the elements. Each exhaust system is engineered without any modifications to the emissions control equipment.
Tanabe high performance exhaust systems are made in Japan at the Tanabe Shiga Factory. From mufflers and piping to hangers and flanges, Tanabe systems are constructed in-house. Each Tanabe exhaust component is manufactured with excellence in mind and high level of quality that meets the requirements of customers who purchase these unique systems.
The exhaust manufacturing section of the Tanabe Shiga Factory utilizes some of the most advanced computer aided machinery, precision laser cutting tools, high quality materials, and employs highly dedicated, skilled craftsmen and engineers. An in-house Bosch four wheel dynamometer is used to test power and function of each exhaust system.
An initial founding member of JASMA (Japan Sports Muffler Association) over 15 years ago, the Tanabe exhaust system is the only one of its kind to be completely manufactured and assembled in-house, in Japan, that is readily available to North America to have the highly coveted ISO9001 certification.
During the manufacturing process, each component undergoes an exhaustive series of tests to ensure that the engineering requirements for material quality, fitment, weld quality, and function are met.
* SUS304 piping is cut mandrel bent. A robotic plasma cutter works on a y-pipe for dual exhaust.
Piping is the first component of the exhaust system to be created. Using engineering data gathered during R&D, the computer is programmed to cut the high grade SUS304 stainless piping to exact lengths and sections. The piping is then sent to the CNC mandrel bender, where engineering schematics and programs are loaded, and the machine produces exact replicas of the engineering department's production prototype piping. When the batch is finished, the piping is sorted and stored for assembly.
* Mufflers are constructed and sealed. Robotic TIG welding is utilized.
The computer is programmed for muffler type and vehicle application. This determines the internal construction type (chambered, loop or straight through) and most importantly, the density of the new Advantex internal packing material to be used. Each main muffler and sub muffler has a carefully calculated formula for packing material, to achieve an optimal balance of flow and noise reduction. High luster SUS304 sheets are cut to length, stamped with the Tanabe logo, and are then shaped according to canister type. The canister and internal components are then assembled and sealed by a highly precise robotic TIG welder.
* Logos are laser etched and authenticity/identifier plates and installed. Muffler tips are installed
Branding and identifier plates are tack welded by hand onto the completed muffler canisters, sub mufflers, resonators and piping sections. These identifiers contain a production number, part number, and the Tanabe logo and series. The identifiers help the engineers track any minor changes they may make to an exhaust system design. Tips are designed and constructed in house, and are sorted according to size, length and diameter for final assembly with the muffler and exhaust system piping.
* Exhaust flanges and hangers are made in-house. A CAD-assisted laser cutter produces flanges.
All hangers and flanges found in Tanabe performance exhausts are constructed in-house. Computer aided design is utilized in manufacture of these components. The SUS304 hangers are bent and sorted according to vehicle make and model. Flanges are cut from SUS304 stainless steel using a CAD-assisted precision laser cutter. The thickness of each flange is carefully determined by the engineering department for each vehicle. On areas exposed to greater stress, a stronger, thicker flanges are used. On areas of lower stress, lighter weight pressed flanges are used. These flanges are manufactured and stored for assembly according to bolt pattern, pipe diameter, and application.
* The highly skilled professionals are involved in every stage of the manufacturing process.
The experienced welders at Tanabe do the job that requires a high level of craftsmanship and accuracy. The result is a reliable, durable, and perfectly sounding exhaust system that provides massive power gains. A final inspection is performed prior to packaging and boxing.
* The finished product is cleaned and carefully packaged. A premium quality Japanese exhaust is ready to provide maximum performance!
The product is given a quality finish. The exhaust system is then carefully packaged, wrapped, and boxed to protect it from damage.