Bilstein Front Inserts
 

I'm rebuilding the suspension of the 78 SC. I have factory Boge struts, and I'm installing new Bilstein Sport inserts. Bilstein's rather generic instructions are to ditch the rubber bump stop from the old Boge dampers. There are no illustrations, although I can learn five additional languages by reading these instructions.

I have been perusing the past posts on this subject...the general consensus is to, indeed, not reuse the Boge bump stop. What about the little rubber washer that comes with the new Bilstein insert? Does the insert cap nut scew all the way down until it's almost seated when I apply the proper torque. I gave it the preliminary once through a little while ago, and it seems to be about 1/4" short of fully seated at the collar, although all of the threads seem engaged.

Also, has anyone actually seen on of those little special spanners Bilstein allegedly distributes with the inserts? Better yet, anyone actually have one they would like to part with?

Thanks!
Pat

I installed Koni reds in place of my Boge originals. The Konis were slightly longer so the cap didn't screw down all the way. This doesn't effect the performance or safety at all. To tighten the cap I used two pipe wrenches with a rag around the cartridge so I wouldn't gouge it.