The DEFCON Bushings, engineered and developed by Mike Phillips (MCPaudiTT/MCPi), are hard anodized inserts for the front bushing of your Mark 2 suspension arms. Installation, with the original Mark 1 bush, and refreshing of your rear bush with OEM MK1 parts yields performance identical to the legendary Mark 1 early suspension components, Other options are detailed below.

Click for detailed picture

Installation pictorial here

The Audi TT “Arms Race”!

You know what it’s about…  The original TT came with the now mythical “MK1” arms.  In 2001 the original suspension parts were changed to what are referred to as the “MK2” arms, and have essentially remained the same through the end of the first generation TT’s production in 2006.  The changes involved in the voluntary recall of early cars and incorporated since include:

1.  Rear spoiler added. 
2.  ESP made standard equipment. 
3.  The front lower control arm design changed.
4. Sway bar and shock rates modified.

The control arm change introduced understeer to the cars handling.  A solution to this change has been attacked on several fronts.  A common approach is to increase the rear and front anti-roll bar diameters.  Another recent solution is to install poly-urethane bushings in the front control arm bush position to dial out some understeer.

The “Holy Grail” solution for TT enthusiasts, though, has been to obtain a set of original MK1 control arms.  This has proven very difficult - and quite costly - if they can even be found at all.  Any original MK1 arms involved in the recall for the above modifications were destroyed.  Many arms have been changed without specific knowledge of their performance attributes during routine work conducted as part of this optional recall.

Now there is a new option in this “Arms Race”.  No longer do you have to scour eBay, hoping to get lucky by finding one of the few remaining MK1 arms or scour scrap yards, in search of ’00 model year cars that had not undergone the recall work. 

Introducing the “DEFCON” MK1 conversion bushings.  These bushings convert your current MK2 arms, allowing them to accept OEM MK1 bushes (urethane MK1 front bushes are also compatible).  The change induced in your car’s handling is significant:  Faster turn in, significant reduction of understeer, and much more communicative steering feedback.  In addition, rear bushes can be replaced with new, unworn MK2 bushes, or with original (softer) OEM MK1 bushes, so you can either duplicate the original MK1 arm characteristics EXACTLY, or tune to your specific needs.

The DEFCON bushing is a precision component, machined from solid 6061-T6 aluminum billet stock.  The part is hard anodized, to guard against corrosion in the aggressive environment in which it must operate and lasermarked to indicate authenticity.  Installation is straightforward, but use of a high capacity press is suggested to ease installation.

All the DEFCON systems are priced in PAIRS.  One set is enough for BOTH the passenger and driver side installations.  DEFCON 1 is the firmest drive/feel available on the market and includes PowerFlex front Poly bushings.  This system is firmer than the original MK1 OEM arms. DEFCON 2-4 systems replace the front bush with an adapter and a MK1 bush.  With DEFCON 2, the rear bush is replaced with the stiffest OEM bush (the MK2 OEM bush).  With DEFCON 3, the rear bush is replaced with the stock OEM MK1 bush – this results in a complete MK1-style arm with new bushes. DEFCON 4 does not replace the rear bush – you retain your (potentially worn) stock rear bush.  Stock bushes DO split/wear with age/use.  You can analyze your own parts to determine if you think you need replacement rear bushes or not, prior to ordering.  Note that Control Arm bolts are “stretch” bolts, and intended for single use only.  It is highly recommended you re[place them when re-installing the A arms. 

It is suggested that all DEFCON adapters and bush replacements be professionally installed by a machine shop capable of pressing out your old bushes and pressing in both the Aluminum adapter Bushing and the Rubber bush inserts. This service can usually be easily sourced locally.

Install notes here (link to be active shortly)

Picture links...

DEFCON 1 : DEFCON front adapters, Pair of MK1 Powerflex Poly Bushings and New OEM MK2 rear bushes.

DEFCON 2 : DEFCON adapters , OEM MK1 front bush, OEM MK2 rear bush:  This will result in a set-up slightly stiffer than the original MK1 configuration.

DEFCON 3 : DEFCON adapters , OEM MK1 front bush, OEM MK1 rear bush. This is an exact replica of the original MK1 arms        

DEFCON 4 : DEFCON adapters, OEM MK1 front bush. This set-up   Retains your existing MK2 rear bush and would be the most affordable install

DEFCON bushing adapters only : No bush inserts or bolts included

LCA Bolts for D1-D4 kits : two bolts and nuts for front of arm, two bolts for rear of arm, Replacement of these parts is suggested as the originals are stretch bolt types.

Subframe Bolts for R32 and 3.2TT:  Due to the need to drop the subframe for instalation on V6 models, it is highly recommended the single use subframe bolts be replaced upon reassembly.        

Unlike performance urethane bushes, if the bush in the DEFCON system wears out, replacements are very inexpensive ($8 or less for a set for the OEM MK1 front bush).  In addition, the DEFCON system provides more feedback and a stiffer response than either replacement MK2 OEM parts or upgraded MK2 urethane bushes

DEFCON Construction:

Precision machined from solid 6061-T6 aluminum Billet stock. Hard anodized and Lasermarked for authenticity.

DEFCON ordering : Defcon kits are shipped Via USPS priority mail (US), or USPS Global priority (Worldwide). Paypal and Credit Cards accepted.

Note: Complete Kits are no longer available as of 9/2/07. Defcon adapters are available and Kit components are outlined in the following link.

Order Adapters (from Modshack) and appropriate kit components from your chosen vendor.

Complete list of Bolts and bushings for a Defcon install

Notes on VW R32 and all Audi 3.2 TT application:

Installation on bot the R32 and the 3.2 TT requires a lowering of the subframe to permit removal of the front Lower Control Arm bolt . This is not difficult, but it does require the removal and/or loosening of the single use stretch bolts used to hold the subframe to the car. It is recommended these be replaced whenever loosened. A Bolt kit is offered with 4 replacements.

A 3.2 specific install and picture write-up can be seen Here!

Paypal preferred Credit card may be faxed or phoned in

Cut and paste into your Paypal statement and forward payment to Modshack@earthlink.net I will acknowledge on receipt.

Defcon adapters : $ 125
Shipping: $

Total: $

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