Clunking after front end rebuild!
 

I have recently done a rebuild on the front end of my 68 911T. I replaced the front struts with Bilstein HD struts, new ball joints, updated with a turbo tie rod kit, poly graphite A arm bushings, added a strut tower brace & of course re-aligned the front also. The car handles GREAT but when hitting certain bumps in the road there is a clunking noise coming from the strut area. I checked everything over again to make sure it was all tight & I had some front wheel bearing play that I took out but the clunking noise is still there. I did not replace the upper strut mounts which I'm now thinking I should have. Anyone have any suggestions on what this noise could be or maybe confirm what I'm thinking with the upper strut mounts?

Could be the strut moving in the strut housings. Jack up the car, and grab the tire at the top & bottem (12 & 6 o'clock) and wiggle it. If the wheel bearings are adjusted properly, and there is significant movement, the strut cartridge is probably moving in the housing.

Did you put in steering rack spacers? If so, you need to adjust the steering linkage. Not doing so will result in a clunk. Another possible source could be the bellows on the tie rods getting caught on the plate that protects the steering rack.

I jacked the car up & there is no movement in the wheel, why would the strut cartrige move? No rack spacers were added.

Did you pull the steering rack when you replaced the tie rods? If so, your clunking may be in the steering linkage. The consensus on this board (do a search) is to loosen both steering linkage couplings and go for a sedate drive in your neighborhood. When your done with your drive, tighten the couplings back up. This worked for me.

Sway bars are classic clunkers and are hard to find when at static rest. Often a good idea to check the mounts and connections.

Check the black rubberized shock tower mounts for the struts. Mine got hammered into small pieces in short order after I refreshed everything else in my front suspension

The upper strut rubber mounts are what Iam leaning towards. The steering rack was not messed with & I have no sway bars.