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
