How To: Coilovers and strut tube modification (with pictures!)

[DSP74]

So reconfirm if you would, the IX insert is shorter than an IS insert and the same diameter.

I've read so much that the Corrado inserts are the ones we need and then I read in a search a guy saying they wouldn't work and that he had to send them back.

[Massive Lee]

There are two Corrado inserts. G60 (4 banger) and VR6. The inserts that will work in an e30 strut are from the G60. They will require an aluminum tube at the bottom as a spacer.

Lee

[DSP74]

Does anyone have a part number for this strut insert?

[mikegar]

i don't smoke. got corrado G60 (9"shaft) since VR6 koni's are complete strut housing. what other corrado is there??? seems to me GC changes the shaft of the corrado shock 8641 1198sport vs GC's 1198spgc

part numbers on page 4

[DSP74]

Yeah but on page 4 there seems to be an indication this shock isn't the right one.....

edit=this guys saying everyones nuts.

If the only issue is the shock shaft length then they will still work. So the diameter of the shaft is the same?

[mikegar]

he said that the non gc ones had some play while it seems that gc modified them.

[etxxz]

GC's and G60 are the same shock tube hence neither of them is a tight fit inside the strut..atleast not as tight as stock, but they work.

GC modifies/changes the shaft so to not make it as long. Regardless, if you want to build the coilover right, you have to put spacer on the top AND bottom of the GC shock otherwise the coilover spring separates from the hat under lift/jack up car. You want to make sure that the collar nut and the spacer directly under it hold the shock snuggly. the bottom one won't matter so much as long as it holds the shock from underneath since the top spacer is taking care of all degrees of freedom.

[Massive Lee]

The spacer at the bottom is well known. But first time I hear another spacer is requied on top. What's the point? Corrado inserts are used in shortened struts to alow more suspension travel when car is heavily lowered, and avoid bottoming out. Using a spacer on top goes against the principle.

Just curious.

Lee

[DSP74]

Will the Koni bottom out internally before being fully compressed? I'm betting the VW insert will and the GC won't. In which case a nice long progressive bump stop is probably a good idea....

Not that it isn't anyway.

[etxxz]

The spacer at the bottom is well known. But first time I hear another spacer is requied on top. What's the point? Corrado inserts are used in shortened struts to alow more suspension travel when car is heavily lowered, and avoid bottoming out. Using a spacer on top goes against the principle.

Just curious.

Lee

i see what you're saying and i've dont it to all three of my e30's (2rip). You won't take away from the travel or bottom out. What i'm explaining is how the shaft is so long, that if you don't want the spring separating from the hat you'll want that spacer up top. otherwise you'll get this when you track/bounce or jack up the car:

that's a good 3.5". i guess when jacking up the car doesnt matter, but when driving/tracking...idk, those are e36 struts w/ e30 collar nuts, GC e30 koni's, and all e30 stuff pretty much....i had to go back and change some things. PITA.

still, the spring will probably bottom out before the shock in either scenario...

[DSP74]

is it a possible issue with using the E36 strut housing?

Is all experience with those inserts using E36 parts?

[Massive Lee]

It si completely normal that, when using coil-over springs, there is such a gap between the top of the spring and the spring plate. Most racers live with it. But as it is not legal on the street to have loose springs, then a pair os helper springs will do the job. helper springs are made from flat sheetmetal and have virtually no rate. They only push the main springs up.

[DSP74]

Right. And that's what I'm planning to use. If I have this issue. I'm just thinking that if strut housing, shock, shock shaft and spring lengths as well as sleeve position should rid us of the spring droop

[etxxz]

helper springs definetly work in that case. (that's not an e30 is it?!)

Its also good to mention that the G60/GC koni fits perfectly snug into the e30 collar nut and that holts the shock perfectly still in place.

is it a possible issue with using the E36 strut housing?

Is all experience with those inserts using E36 parts?

same thing w/ e30 just to eliminate doubts. i've done both. that pic up there is an e30-e36frankenstein i made for my 5-lug.

[mikegar]

what are the advantages of having the sway bar attached to the strut housing?