Porsche Enthusiasts Club Forum

I've been looking for alternative to using old strut sections or £££'s on ready made threaded inserts,
I finally came accross these ehaust nuts for a motorbike https://www.ebay.de/itm/Motorrad-Uberwu ... 1502687527?


Start by grinding/sanding the crimped tops until they are flush with the top plate


Remove inners


The bilstein top nuts have a slight recess, here I marked the cut line just below the threads, exact positioning comes later


After removing the zinc coating and cleaning the inside of the srut,
there is a slight amount of play,
therefore I decided to drill 4 8mm holes so I can plug weld,
this will give great strength to the finished strut


The bilstein nut screws down a total of 6 turns, in this photo you see it fully screwed in,


wind it out 1 and a half turns, s in this photo


position strut insert, threaded insert and nut (backed off 1 and half turns) into the strut housing


Mark on the insert the top of the strut


Wrap two layers of tape around insert (just up to the end of the threaded section) to take up play and to centre insert,


Slide on section which was cut off earlier up to the scribed mark


Place insert into strut


As the top of the strut was carefully ground down, this will be nice and square and will help with alligning the insert


Use a clamp to keep it in position


Tack weld and then check it, on mine there is about 4 1/2 - 5 threads used,


When you are happy that everything is correct, weld up the holes


Followed by the top of the strut


Grind/sand and little skim of filler just to neaten my (just learning) TIG welds


Prep and Primer


Final coat in Bilstein yellow (John Deere yellow)

Thanks for looking
Any questions, Ask away
Steve

I really appreciate you making this post Steve. Despite their struggling as a result of FB pages, I think that a traditional forum has FAR more to offer and posts like this help.

Simon

Great post Steve, enormously helpful and straight into my Bookmarks!

As Simon points out, this is where forums surpass themselves for info and detail you can go back to

Many thanks again for making this look so much more doable

Just an update, One Bilstein insert arrived but the other one got lost (2 different suppliers)
Finished it off with a seal I got off ebay, https://www.ebay.com.au/itm/Cyan-Blue-U ... 2749.l2649

Good writeup J.C. - Thank you

Nice, well done!