Passat (B6) :: Front Suspension - Harsh Over Bumps

I have been working on my front suspension for last 4 to 5 months and not getting any luck getting rid of the harshness over bumps and the large amount of energy from hitting bumps that transmits back into cabin both from the chassis and steering wheel.

I solved one issue that can be read through on my post for "Bad Engine Mounts ?" but still does not feel solid like it should over bumps. So far this is what I have done.

- New LCA Bushings (solid rubber style rear and Whiteline front)

- Koni FSD Shocks

- VW DG Sport Springs

- 034 Density upper strut mounts

- Meyle HD Sway Bar Link

- ECS Sub Frame Bolt Kit

Had VW Dealer put on rack last week and they could not find any looseness any where in front suspension. In desperation I took LF suspension apart yesterday to see if there was anything that I could figure out that would cause the suspension to not absorb the energy and create this harshness I am feeling.

My first thought is to go back to stock upper strut mounts, there is some give in the OEM mount compared to the 034 Density mount, they are rock solid! The other thing I noticed is the sport spring is rubbing on the strut spring perch.

[IMG][/IMG]

Then after look at profile of OEM spring on bottom and new sport spring I noticed they are different, OEM is kinda like a hook and sport spring is round.

OEM matches strut spring perch perfectly.

[IMG][/IMG]

Sport spring is tight

I would consider putting OEM spring back in but really would like to lessen wheel/fender gap and OEM springs look like they have sprung, won't stand up straight on bench cause they are curved after they came out of OEM struts. Also, B6 has no rubber insulators where springs seats into strut, my B5.5 has rubber insulators both top and bottom.