Interactive crossovers (sample apps) use a shim diameter that is larger than the stack clamp. The larger crossover diameter transfers force from the face shims directly into the high speed stack forcing the high speed stack to deflect before the crossover closes. Interaction with the high speed stack softens the crossover closure event.

Shim ReStackor analysis of an interactive crossover tested by MXScandinavia on Thumper Talk produces a crossover closure velocity of 60 in/sec. However, the MXScandinavia dyno could only test to shaft speeds of 40 in/sec.

The test illustrates a typical dyno frustration. At the velocity limit of the test no unusual behavior is observed. However, the crossover gap has not closed creating uncertainties the shock absorbers high speed performance.

Shim ReStackor helps relive those uncertainties with the capability to compute high speed shock absorber performance and evaluate crossover closure velocities and the effect of valve port flow restrictions that kick in beyond the limits of conventional dyno testing.

A faux crossover gap never closes. Faux gaps are created by large crossover shim diameters, stiff low speed stacks or soft high speed stacks that do not produce enough force to close the crossover gap. MXScandinavia provides dyno test examples of faux crossovers.

In dyno testing, faux crossovers behave like a interactive crossover. Changes to the low or high speed stack changes the damping force leading many dyno tuners to believe the crossover gap is active.

However, the crossover gap height never changes as the shim stack deflects. The crossover shims could be moved further up in the stack forming a simple tapered shim stack with the same damping force.

In dyno testing, there is no way to know the crossover gap is faux until the shock is pushed to high enough speed to observe the crossover closing. Soft closures of interactive crossovers make those events difficult to spot in damping force data.

Interactive crossovers (linky sample apps) use a shim diameter that is larger than the shim stack clamp. The larger crossover diameter transfers force from the face shims directly into the high speed stack forcing the high speed stack to deflect before the crossover closes. Interaction with the high speed stack softens the crossover closure event.

MXScandinavia dyno tests on Thumper Talk evaluated the performance of an interactive crossover configuration.

Shim ReStackor analysis of the configuration shows the crossover closes at a shaft velocity of 26 in/sec. Due to the shim stack configuration there is virtually no change in stack stiffness or damping force at the crossover closure confirming the dyno test results.

A common misconception in shim stack tuning is the face shims control low speed damping and the stack taper controls high speed. Dyno tests and Shim ReStackor show shim stacks do not work that way.

The dyno example below from the MXScandinavia thread on Thumper Talk replaces the 0.2 mm shims in the stack taper section with stiffer 0.25 mm thick shims.

The dyno test results show the shim stack is stiffer everywhere across the speed range, not just at high speed. Shim ReStackor calculations (lines) show the same thing.

High speed damping can be stiffened by tuning the crossover or softened using a preloading ring-shim (linky, fundamentals).