Porsche Enthusiasts Club Forum

I've got a knocky front suspension strut on the S2, having replaced the wishbones, ARB bushes and tie-rod ends the knock isn't steering related. Investigations showed a fair amount of play at the top of the wheel and it was confirmed when I could grab the damper rod and wobble everything around.

So, I bought a set of strut inserts having cross referenced what fitted what - or what I thought fitted everything else .. yeah - you know where this is going already doncha!

So, today I hauled everything apart, pulled the strut out and un-springed it (I even bought spring compressors especially!), dug out my big stilsons to unscrew the strut cap and set to it. I was delighted that the cap started to turn rather than be rusted solid - not so delighted when I saw that whilst it was turning it wasn't actually advancing off the strut body. Hmmm. Figuring it was crimped on I tapped the cap off with hammer and drift. When it came off I saw that contrary to what I was expecting the shock insert was actually secured by having the top of the strut casing folded over effectively making the insert non-removable.

My first thought was "Bollocks", the second was WTF am I going to do to fix the problem?

So - does anyone have any suggestions regarding the options I have?? Can I modify the strut to take these inserts?? I'd like be able to use the inserts rather than not, but I'd also not like to be forced into spending too much more dosh on account of having spent far too much already...

Any feedback appreciated

Greg

only the early 944's have inserts. BUT hhave you bought aftermarket struts (koni pehaps?) which require the strut body to be modified. instructions should be included if this is the case. although it sounds like you have the wrong parts.

The S2 struts were not designed to be rebuildable with inserts, but you can fit them if you are handy with an angle grinder.

Full instructions here:

https://www.paragon-products.com/kb_results.asp?ID=50

Yep I've modified sealed S2 struts to have a screw top and take a 'normal' B6 Bilstein insert. It turns out that the outside diameter of normal old style 944 screw top strut casings are a tight sleeve fit within the S2 housing tube. So use a pipe cutter to cut about four inches of the top of some old housings with threaded tops and then cut the S2 housings as near to the crimped top as you can. You can slide those old threaded tops down into the S2 housing. Its not rocket science to work out what length the new modified overall length needs to be and then weld it up super strong!

The bottom of the S2 strut housing is domed and centres the strut nicely as the threaded top collar tightens it down.

Pics on the way if I can find them

Different from Pauls mod above as for Bilsteins not Konis.

Cheers Rob

It's looking like I am an actual and complete cock ...


The inserts I have don't have a securing bolt at the bottom as they are I guess secured by the screw collar at the top of the other type of strut (which Sachs have very kindly supplied for me to use lol...)

If I want to use these units then I'm going to have to do a bit of fettling as Rob describes ..

Off on a hunt for a pair of knackered Turbo struts ..

G

Greggers -
I replaced my stock S2 with Koni Sport adjustable front and rear. The Koni front is an insert to the original strut casing, with a bit of a mod to make it fit. The key provided (top end via the engine bay) allows you to adapt the hardens ratio of said strut ie: soft, medium, hard ride. Mine is set at medium, like the backs... I also replaced the front springs with lowered H&R (a Koni product) specific for the S2. Most springs are much worn after such times, so is worth the upgrade - my car now handles like a train... Hope my views help...

Dave

If it helps golf mk2 struts are ripe for butchering for the threaded tops, they're far more abundant than early 944/924 struts and are near as damn it the same I believe.

Or send back the inserts you have and buy some Koni's. More expensive, but will give your s2 the dampers it deserves

Thanks Rich, the Golf tip is just what I was hoping for ,...

Sadly, my car budget has been worn thin, very thin recently so Konis are out of reach for the time being, but the new units are undoubtedly going to be better than the units that are on there at the moment.

I had a look at the old damper - fuqued might sum it up, not much damping compressing the unit but much more rebound, in fact it was an effort to pull it up! The new Sachs units are OE for the Turbo AFAIK and are much more 'gassy' in that it takes a lot of effort to compress it, and it pumps back quite firmly.

Down to the breakers I think..

Cheers guys

Greg

Yes - can confirm that Golf struts (mk2?) will also do... the big advantage in my mind is that normal inserts can now easily be used on my S2. The B6 Bilsteins have been great for a couple of years now - not quite as hard as Spax maybe. Fill up the housing with old oil before screwing up tight as there is a larger space around the insert at the bottom. Its all held tight enough, but the oil helps dissipate heat. I think I might have cut more than 4 inches of the old smaller diameter struts so that they laterally supported the inserts further down inside the S2 housings if that makes sense...

Pics as promised:

S2 crimp top cut off


Screw top strut end being slid into place


Welded up, trial fitting:


Cheers Rob

Rob - that's great mate!

As I said, I just need to find some old struts now...

Muchos

Greg

I have some old S2 struts with springs and top mounts if you want them.
I am in Ripon N Yorks.

Nick

... a pleasure Greg.

I am quite proud of this mod, fairly adventurous for me given my tech ability. My local Porsche indie garage was suitably impressed too and reckoned it was a sound job. I can't claim it as my own idea, I saw it mentioned on Rennlist somewhere a long time back - someone was laughing and calling them 'Frankenstein struts' if you want to search....

A big pipe cutter is the way to go - effortless square cuts each time.

Before anyone thinks just using older strut housings on an S2 would save the bother of cutting and welding, its worth pointing out that the two bottom hub carrier mounting flanges and holes are spaced differently. This results in having to elongate holes and use packing shims, not really a good idea in this most critical area.

Cheers Rob

I'm having a little giggle at the prospect of 'Frankenstruts' .... but essentially I think it's a sound idea..

I may have been thrown a lifeline though - let you know how it develops later in the week.

Cheers to all

G