SC/Bilstein strut question
 

So I've replaced a few sets of strut inserts in my time but have never done Bilstein's. I have a '78 SC with Bilstein front housings and took the front insert out. Much to my surprise, it's a Koni! The Koni insert is wider than the replacement Bilstein and fit snuggly in the strut. The Koni also had a threaded cap that screwed onto the top of the insert but won't work with the Bilstein insert. Is there supposed to be a cap for the Bilstein and if so, how would it hold the insert in place? The top of the housing isn't threaded externally or internally. Did someone maybe modify the housing? Am I missing something?
http://forums.pelicanparts.com/uploa...1508863298.jpg

Either someone has modified that strut housing and removed the upper seal and bushing, or that is not actually a Bilstein strut. (could be a green painted boge?)
Is there a narrow hole at the base of the strut? That's where a bilstein roll pin would be inserted to secure a bilstein insert.

If indeed it was a Boge, it would have either internal or external threads
on the top of the tube. My question is, what was holding the Koni insert that was removed? Your comment on the roll pin is correct, if the tube doesn't have one it's not a Bilstein strut! Also the top Bilstein upper seal and bushing is missing. A lot of folks don't understand that the Bilstein
strut uses an "upside down" insert that has the active piston rod on the bottom as opposed to Boge and Koni which mount the piston rod on top.

The housing itself doesn't look too wrong for a Bilstein with the dust cap removed. The new inverted insert should fit pretty tight (well, it should slide smoothly but have no play.) It goes in shaft side down. What looks like a lip in the photo is actually a separate bushing. I had one wear out recently on my car and I replaced it.

The dust cap / wiper that appears to be missing is press fit and pops off with whack or four from a hammer.

http://forums.pelicanparts.com/uploa...1391102031.jpg

Thanks Matt, I seems to be missing those caps as shown in your pic and the upper seals. *Anyone have a couple of those covers and upper seals I could buy?* We don't have any direct contact with Bilstein but I suppose I could try Google to find them.

They are definitely Bilstein housings. I had to drive out the roll pin to get the Koni insert out.

Elephant sells a shortened version of this seal, if you can't find any originals.

***Paging Dimitry for link to Pelican catalog!***

I have a few spare bushings if you need them

I spoke to Shannon at Elephant Racing and there are more problems with these struts than meets the eye. Apparently, there's an upper bearing that is missing as well. Probably more trouble and $$ than it's worth to put them back to stock. Thanks for all the help guys.