HELP! SWB Strut Insert Crisis!

scarroll · 01-09-2011, 02:13 PM

I've been following the steps in a couple of other threads for installing Bilstein inserts into an original Boge strut. They call for using the supplemental spacer at the bottom of the insert for 1968 and earlier cars. My car is a '66 911. I dutifully drove the spacer into place, and now the insert doesn't get quite far enough into the strut to engage the threads.

Sticking a measuring tape into the strut to check things out, it appears that there may be another 1/8" of space between the bottom of the spacer and the bottom of the strut, but I've pounded the heck out of it already. The bottom of the strut appears to be concave, and I think the spacer is as far down as it's going to go. When I measure the total length of the strut and compare it to the length of the insert, it's sort of looking like I should not have used the spacer, but that's contrary to everything I've read. As it stands now, I can get the insert's threads to barely touch the threads on the strut, but not enough to bite. Even if it did bite, I don't think it would pull down all the way.

Your suggestions, please!

BURN-BROS · 01-09-2011, 07:25 PM

Are you sure you have the original strut housings?

scarroll · 01-09-2011, 07:53 PM

Fair question. I'm pretty sure they are the original Boge struts. They are black (in what appears to be original paint). The dust cover is stamped with the Boge name and two part numbers: 1-0211-32-525-0, and 901 341 067 06. The insert was not of the modern sealed variety, but a loosy-goosy contraption that spewed oil all over the place when the shaft was moved up or down. Does that sound like the original Boge innards?

scarroll · 01-09-2011, 07:59 PM

Oh, and I forgot to mention that another response (on the S-Registry) described having to grind the spacers down just a bit in order to slide them to the very bottom of the struts on a '67 912. That is the second time I've heard reference to that. Since I bought the inserts (and the accompanying spacers) from Pelican, maybe they can chime in with advice here.

BURN-BROS · 01-10-2011, 06:44 AM

Here are a couple of pics to determine early vs late. Early strut housings are 2 piece units that bolts together @ the ball joint.

Early

Late

chris_seven · 07:13 AM

I have found that there can be a couple of millimteres difference in the internal strut body length and that the bottom is slightly curved. A relativle thick spacer can cause a few problems.

I think the best way to make the spacers you need is to make several of about 1 mm thick and to knock them down into place with the old insert. This will allow the 'spacer' to fit the curve at the bottom of the insert and give a good load bearing surface.

Fit just enough to take up the axial clearance and still let the lock nut work. If you fit them one at a time they will take the shape quite well.

I youd also use a few ccs of oil to stop them rusting unless you use stainless steel.

scarroll · 09:23 PM

Ok, I have good news: I took the strut to a local shop and had them remove the spacer. (They fabricated a hook for their slide hammer that fit the underside of the spacer nicely.) I measured the strut again, and confirmed that using the spacer was appropriate. The strut is the early variety shown in the top picture above. Then, I ground the OD of the spacer just a bit, as suggested by a couple of fellows on other boards. I suppose I removed a few thousands around the circumference. The spacer dropped to the bottom of the strut cleanly, and the insert tightened up properly.

Now, I have to do the other side. I expect it'll go a little faster. Many thanks to all who replied!