From Problems to Performance: The FullFlight Racing Transformation Story
ATV A-Arms, Problem Solving, Elite Series, Quality Improvement
The Challenge: Changing the image of a company into Excellence
When FullFlight Racing's new ownership took over in 2019, they faced a company with a reputation problem. Instead of running from the criticism, they did something unprecedented—they embraced it as their roadmap to excellence.
The team spent months digging through message boards and forums dating back to the early 2000s, documenting every single customer complaint on detailed spreadsheets. Their mission was simple but ambitious: fix every problem, eliminate every issue, and rebuild the company from the ground up.
AThe Squeaky Heim Joint Crisis: Problem Solved
The biggest complaint? Squeaky heim joints that drove customers crazy and became synonymous with the FullFlight Racing name. But this wasn't just about noise—it was about quality.
The old economy heim joints used cheap materials that created metal-on-metal contact under load, causing the characteristic squeaking. Worse yet, many customers tried to fix the problem by spraying WD-40 on the joints, which actually accelerated wear by washing away existing lubrication.
The Solution: By 2022, FullFlight Racing completely eliminated all economy heim joints and replaced them with Teflon-lined chromoly heim joints. The chromoly construction provides superior strength, while the Teflon lining creates a self-lubricating surface that makes squeaking physically impossible.
AlBall Joint Evolution: From Good to Great
The improvements didn't stop with heim joints. FullFlight Racing evolved their entire ball joint system through three generations:
Phase 1: Moved from heim-style ball joints to Teflon-lined hieim style ball joints for improved durability and reduced maintenance.
Phase 2: Elite Series 1.0 introduced conventional sealed automotive-style ball joints that provided superior protection against contamination and longer service life.
Phase 3: Elite 2.0 series features upgraded automotive ball joints with three-quarter inch threads for maximum strength and reliability.
The Elite 2.0 Revolution: Complete Redesign
In 2024, FullFlight Racing launched the Elite 2.0 series—a complete ground-up redesign enabled by their new Bentech Dragon manufacturing machine. This wasn't an upgrade; it was a revolution.
Key Elite 2.0 Innovations:
- Upgraded automotive-style ball joints with 3/4" threads
- Heavy duty Teflon-lined chromoly heim joints for uppers
- Fixed lower Delrin bushing system (simplified but stronger)
- Extra crossmember in lower arms for added strength
- Complete discontinuation of Legacy series
The simplified design eliminated adjustment complexity while actually improving strength and reliability—a perfect example of how customer feedback drove innovation in unexpected directions.
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Total Company Reconstruction: Everything Changed Except the Name
The product improvements were just the visible part of a complete company transformation.
What Changed:
- Facility: New purpose-built manufacturing location
- Equipment: Every single piece replaced with state-of-the-art systems
- Processes: Updated powder coating, fixtures, and quality control
- Team: New employees with advanced manufacturing expertise
- Systems: Comprehensive quality assurance and documentation
What Stayed: Only the FullFlight Racing name remained from the original company.
Customer Service Revolution: Available When You Need Us
One of the biggest transformations involved customer service. FullFlight Racing now provides technical support from morning through evening, including weekends and holidays. The team doesn't just answer questions—they solve problems, provide installation assistance, and help customers optimize their suspension setups.
This isn't traditional customer service; it's technical partnership that ensures every customer achieves their performance goals.
AThe WD-40 Discovery: Education Saves Components
During their investigation, FullFlight Racing discovered that many customers were unknowingly damaging their suspension components by using WD-40 on heim joints. While well-intentioned, WD-40 actually dissolves existing lubrication and accelerates wear.
The Solution: FullFlight Racing now educates customers to use dry silicone spray instead, which provides lubrication without attracting dirt or washing away protective films. This discovery led to comprehensive maintenance education that helps customers protect their investments. However we highly recommend using nothing on the joints since they are fully self-lubricating telfon inside each jointl.
The Results: From Criticism to Industry Leadership
The transformation timeline tells the story:
- 2019: Company acquisition and comprehensive feedback analysis
- 2022: Eliminated squeaky heim joints, introduced Teflon-lined chromoly joints
- 2024: Launched Elite 2.0 series, discontinued Legacy products
Today, FullFlight Racing stands as proof that criticism, when embraced systematically, becomes the most valuable blueprint for excellence. The company that was once known for squeaky joints is now recognized as an industry innovator setting new standards for ATV and UTV suspension performance.
What This Means for You
Whether you're dealing with broken A-arms, suspension bottoming out, or simply want the best performance from your ATV or UTV, FullFlight Racing's transformation story demonstrates their commitment to solving real problems with innovative solutions.
The Elite 2.0 series represents the culmination of five years of customer feedback, advanced engineering, and manufacturing excellence. Every component is designed to exceed expectations and deliver the performance improvements serious riders demand.
Ready to Experience the Difference?
Shop FullFlight Racing Elite 2.0 Series: https://fullflightracing.com/collections/atv
Contact Technical Support: https://fullflightracing.com/pages/technical-support
Watch the Complete Story: https://youtu.be/9oy3rUr-AIU?si=PpLQPbn0hWZBaJeS
About FullFlight Racing: Since 2019, FullFlight Racing has completely transformed from a problem-plagued manufacturer to an industry leader in ATV and UTV suspension components. Every product is backed by comprehensive technical support and a commitment to customer success that extends throughout the ownership experience.
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