Problem - Can't Get New Bilsteins to fit into Boge Struts

[Tidybuoy]

Hi

I just purchased "new to me" Boge Struts from an '86 Carrera because I needed 3.5: caliper spacing. I also purchased new Bilsteins for these struts.

The problem is that the bilsteins fit until the last inch and then get stuck. The struts were in great shape and don't appear to have been abused or bent.

I poured a little oil into the struts first hoping that that would help the new inserts slide in, but no luck. Now I'm wondering if the oil is preventing the insert from going any farther if there is no way for the oil to escape up the sides (assuming the seal is tight). And now it's looking like the new inserts aren't going to come out of the struts.

Does anyone have any advice? I'm starting to feel desperate as I already spent too much on the struts, new Bilsteins, and then powder coated the struts - this doesn't even include the new brakes.

Thanks for any advice

[Driver_X]

Can you post of photo of the both the struts and the inserts? That might help to determine if you have a mis-match.

[Tidybuoy]

I'll take some photos tonight.

I did look up the par numbers when I got everything but I'm going to do that again tonight.

Thanks,

[john walker's workshop]

get the oil out. then take the paint off the bottom 2 inches of the insert. a bench grinder wire brush works good. had to do that on a few to get them to fit. hopefully no powder paint went inside the strut.

[Tidybuoy]

Thanks John,

No powder went into the struts as they kept the caps on while coating and it looked like bare metal in there to me. I think the sanding may be my only option - I just hope I can get the struts out without having a temper tantrum in the process

I'm wondering if I can use some pb blaster instead of the oil?

[Krieger914]

Can you turn the struts upside down and let the oil run out? How about some compressed air in between the can and insert to break the suction?

[Krieger914]

Maybe, very, very carefully drill a small hole into the bottom of the strut can (1/16") and not into the insert. Use compressed air to force it out. Use some seam sealer in the hole after to close it up.

[neilschelly]

Yeah, definitely get the oil out. In my case, I had applied the Bilstein part number stickers to the struts I got before trying to put them in - those stickers meant I couldn't get the strut all the way in either. It's a pretty tight tolerance, but should go right in when you clear the way.
-Neil

[Tidybuoy]

Thanks all.

I didn't get any photos taken because I got home too late.

I guess I thought oil was a good idea because on my old BMW, when I replaced the boge inserts, it called for filling the strut tube with oil first. This was to aid in cooling transfer.

Thanks,

[kodioneill]

DO not drill a hole in the strut. Check for a leftover valve in the bottom part of the tube. Some of the old struts were not inserts but integral and there is a small quarter size valve in the bottom that prevents the insert from going all the way in. To get the oil out insert a hose 1/2 in dia all the way in to the bottom of the housing jam in a rag at the top the use a air gun to blow in compressed air until the oil runs out of the hose have a container handy to catch the oil.

[POORSH]

Vern,
Did you eventually get the Bilsteins to fit? I will be going through this in the near future.