Trouble removing Boge strut inserts

[EGlass911S]

I have a 1976 911S that I was having trouble extracting one of the original Boge Strut inserts that had been there for 35 years. It was really hung up and I didn't want to have to remove the entire Strut from the car. So I used a combination of the PB blaster and a tool that I made from threaded pipe that I got from the hardware store. My method is pretty straight forward. I shot a ton of PB blaster down into the strut and let that work while I went to the hardware store. At the hardware store I purchased some threaded pipe 1 ¼” diameter and 6” long, a connecting collar that threaded onto one end of the pipe, a large nut that screwed onto the other end of the pipe, a second connecting collar that was 1 ½ diameter so it doesn’t thread on the pipe and some washers. As you can see from the attached photos, the collar on the bottom threads onto the pipe to allow you to adjust to the perfect length. The collar above the nut is 1 ½ diameter so it doesn’t thread on the pipe and thus moves freely. Then I reinstalled the original locking collar that holds the strut insert in the strut but just about half way so there was a little over a ¼ of an inch gap inside the strut. Then I extended the inserts shaft as far as it would go and I slid threaded pipe tool I made over that. Next I put a collar that was just big enough to move freely over the pipe threads. Then I put the washers on top of that and secured the whole thing with the shafts top nut. Then by rotating the nut on the threaded pipe I was able free up the old insert and remove it.

[Peter Zimmermann]

Nice solution, but they usually just pull out after using a dentists pick to remove the upper o-ring.