Cutting Down Bilstein Internal Bump Stops

[jeffnhiscars]

Im about to install my replacement strut housing and now would be the time to tackle this annoying issue. It looks like I just need a 2 prong device to unscrew it but always good to confirm when dealing with high pressure stuff.

Is there something off the shelf that works and how best to clamp the yellow housing so I dont damage it ?

Any other FYI's ?

Thanks

[Balleristic31]

Also interested in this procedure.

[LJ851]

It's pressed in , not screwed in. Get a chisel or similar and gently drive the silver cap off. It is attached to the damper rod and you are not entering the fluid cavity (pressurized) part of the strut. This will expose the bump stop, remove however much you want with a razor blade.

Edit: Also, the yellow outer shell is just a covering, It's inner surface is not what the shock piston rides on (seals against) like a conventional strut. Gently clamping it in a vice is fine.

[jeffnhiscars]

THIS is what I love about this forum.

There was no lip per se but a few gentle taps at almost a 90 gave me enough room to get the screwdriver in there. I had the yellow tube on a 2x6 held down just with my foot.

It is very soft rubber yet hard enough to jar my bones when I hit a pot hole. Im thinking to remove the bottom half rather than the top.

Make sense ?

I withdraw the question. The top is flat and if I remove the bottom portion there will still be a taper left at the bottom.

[CW325]

Thanks for posting pics, I might be doing this soon.

[jeffnhiscars]

Pics make all the difference. This was a breeze, especially since the strut was already out. Doing it from scratch I'd say an hour\side plus PITA time depending on how long it takes you to get unbolt everything. My tie rod end and ball joint dropped easy. Unbolting the strut retaining nut without a special tool took...well...days. In the end I grabbed the shaft (strut that is) with channel locks just below the top spring pad where the model # is (so as not to damage the important part). Then w a 19mm socket I just gave it a sharp smack with a 3lb masons sledge.

The 1st pic shows you how I cut it along with the special BMW tools I used. Just ask for StanleyEstwingXacto (SEX for short:)

Now I just have to figure out how I managed to reinstall the strut housing 180 degrees out

PS You do need spring compressors to do this. I got mine at HF for $12 and remember EXTREME CAUTION CONTENTS UNDER PRESSURE !!

[nrubenstein]

For what it's worth, I used channel locks to grab the bottom cap and twisted it off.

[jeffnhiscars]

For what it's worth, I used channel locks to grab the bottom cap and twisted it off.

I did try that. Perhaps its cause I have the 30mm strut or just the way the Sport is built, but I couldn't get a decent grip on it.

The sad part is that now I have to pull the other strut and cut IT down...unless there's a thread titled "What Happens If I Drive My Car with One Cut Down Bump Stop and One Whole One and Can I Compensate by Increasing Toe In on One Side":-?

[AE86]

Just curious but does anyone know if Billy HD's and Sport's have the same length and style bump stops?

[jeffnhiscars]

Just curious but does anyone know if Billy HD's and Sport's have the same length and style bump stops?

The half I just removed is 1.5" so figure 3" on a Bilstein Sport PN P30 0334 HO. Keep in mind thats for the 45mm housing and is a 30mm strut VS 36mm for the ones that go in the 51mm housing. The PN on this stop is B36-126A 6 FWIW

[AE86]

nrubenstein or LJ851, how do you re-install the BOTTOM CAP that holds the shocks together? I read from your posts that you were able to "un-screw" and/or "tap out" the cap, so what method do you use to re-install? Thanks for your input, I'm gonna be taking apart my HD's soon.

[ak-]

Put the cap back on and tap it on the floor a few times.

[kennyvb]

Wish I saw this before installing my Billy Sports

[M-technik-3]

Wish I saw this before installing my Billy Sports

Not hard to remove them and on another note you might be able to do a harder durometer for stops.

[JGood]

Thanks for this info and pics! Will be doing this to both of my e30's.