koni inserts for boge struts

[theo5042]

Hi all.
Maybe some can help.
I have bought some koni inserts (8641-1039 sport) to fit into my boge struts(1980 sc).
The insert goes in ok,but the gland nut fouls the top of the insert(just)not allowing it to thread all the way down.Is there a different gland nut for this application or do I need to machine the inside bore of the nut?
Also do I need some sort of bush to centre the bottom of the insert in thed tube.
Thanks in advance
Theo

[Trackrash]

I believe your struts are threaded on the outside at the top and a large nut threads on to hold the top of the insert in place.
There should be a large washer or ring that fits over the top of the insert. If you have the correct washer the original nut should tighten and hold the top of the insert securely in place.
The bottom is held in by friction.

[theo5042]

Thanks for the reply Gordon.
My struts are threaded on the inside,there is about two and a half millimeter play all round between the insert and the tube.The nut tightens down on top of the insert but only threads a few threads down,looks like it needs to go a few more turns.I have read about a gland nut that is available that would complete the conversion,I was hoping someone on here may have done this conversion and could have some input.
Thanks again
Theo

[Trackrash]

I thought only the older struts threaded on the inside. I had this same problem a couple of years ago. You can read about it here and see pictures of the nut I had to use.
Front Koni reds/Rear Koni Yellows?
My struts are Konis however. Somewhere on Koni's web site there is a list of the different nuts available. It is hard to know which one to use. You could call Jason at Paragon products as he is THE man with the knowledge.

[theo5042]

Thanks for that.
I have sent Jason an email.
Basically not a huge problem,I think that if I machine out the nut a touch and make up a spacer to allow the nut to seat on the insert I should be ok.
Thanks for the input.
Theo

[Oldporsche]

Being familiar with earlier model struts, 1969 thru 1977, I suspect little change.

The original Koni Struts, held Koni inserts, and used their own "koni" thread spec. Thus Boge Struts used "Boge" thread specs likewise. When inserting Koni inserts in Boge struts, I use a nut that fits the thread of the strut. The specs call for the nut to thread into/onto the top of the strut but not bottom out in the threads. I have also had to make bushings to center the strut insert in the struts. I think I have even enlarged the opening in the strut top nut to accommodate some strut inserts. Don't forget to add enough oil to the strut to fill the area around the strut. This is necessary to transfer the heat generated by insert to the surface of the strut.

[theo5042]

Thanks for the input.

[micheloaks]

As I am about to install yellow koni 8641 1039 sport external adjustables into my 71t am also interested to know whether the 3mm approx gap between the top of the strut housing and the new supplied gland nut is correct? Or should I modify the gland nut - slight bevel on the I.D to allow it to fully screw down on the strut housing. The gland nut fits snugly around the top of the strut. Also does there need to be a Lower bush inserted into the tube to centre the strut?

Car previously had Sachs fitted and the old gland nut fitted tight to the top of the strut housing (tube). No gap?

Also was advised to put some oil into the tube? but another suspension shop said no?

Confirmation appreciated

[Trackrash]

As I am about to install yellow koni 8641 1039 sport external adjustables into my 71t am also interested to know whether the 3mm approx gap between the top of the strut housing and the new supplied gland nut is correct? Or should I modify the gland nut - slight bevel on the I.D to allow it to fully screw down on the strut housing.

Do not modify the nut. You want some threads still showing when the gland nut is tight.

Also does there need to be a Lower bush inserted into the tube to centre the strut?

None is needed.

Also was advised to put some oil into the tube?

This is not absolutely necessary, but I used anti-freeze. It will help transfer the heat from the shock to the strut and if you have a leak you can know if it is the insert or not.

[micheloaks]

Gordon thanks for the heads up!

Also noted that there was a small hole at the top of the gland nut just under the flange that exits through the exposed threads?
Inserts now in.now to replace ball joints , tie rods, bushes an...

Again thanks
Cheers michel

[JAR0023]

FWIW the switch from internal threads to external threads on Boge struts was mid year 85.

J