944 GBC - My 1992 944 S2 3.0 - The story so far !

PAUL RUDDY · Mar 12, 2015

ORIGINAL: RS2000CUSTOM

Right after a couple of coffees at the engineers we now have 2 solutions

1/ An internal sleeve (similar to what others are doing with "cut off" old strut threads)

2/ An external collar that fits over the original strut

The internal sleeve will look more "OE" when finished

But the external collar will allow the Bilstein protective bellows (supplied with the insert) to be secured correctly

I will also be fitting a nylon sleeve lower down inside the strut casing to centralise the insert

Have even sourced a RAL powder coat colour that is similar to Bilsteins

I aim to media blast the casing, attach the adaptor, powder coat the strut and fit the insert - job done

What may be feasible is strut casings converted on an exchange basis

Number 1 for me please ...[

]

RS2000CUSTOM · Mar 12, 2015

ORIGINAL: PAUL RUDDY

ORIGINAL: RS2000CUSTOM

Right after a couple of coffees at the engineers we now have 2 solutions

1/ An internal sleeve (similar to what others are doing with "cut off" old strut threads)

2/ An external collar that fits over the original strut

The internal sleeve will look more "OE" when finished

But the external collar will allow the Bilstein protective bellows (supplied with the insert) to be secured correctly

I will also be fitting a nylon sleeve lower down inside the strut casing to centralise the insert

Have even sourced a RAL powder coat colour that is similar to Bilsteins

I aim to media blast the casing, attach the adaptor, powder coat the strut and fit the insert - job done

What may be feasible is strut casings converted on an exchange basis

Click to expand...

Number 1 for me please ...[]

No 1 will probably not happen

My engineer has looked at it again and prefers to go with No 2

No 2 will be a lot stronger but more importantly the Blue Bellows will fit perfectly on an external collar

As for the OE look that will be irrespective as none of it will be seen as the bellows will be covering the collar area anyway

RS2000CUSTOM · Mar 17, 2015

Well Porsche OPC Sutton Coldfield done good again today

I have managed to source all the bolts, washers and fittings etc ready for when I fit my new front struts

RS2000CUSTOM · Mar 25, 2015

Well plenty has happened lately [&:]

Firstly at the weekend the genuine Porsche immobiliser wouldnt operate and the car was stuck (luckily in my workshop)

So most of the dash taken out and got the immobiliser removed

The reason it failed was that a terminal had fell off in the socket that the immobiliser "key" slides into

While I was there I fitted some "anti-theft" devices !

And today I managed to get a lot more work carried out on the original S2 strut casing to facilitate the fitting of B6 Bilstein inserts

Very happy with the results and I will carrying out some powder coating tomorrow

Waylander · Mar 25, 2015

Looking good, immobiliser removal is on the list of jobs to do, just don't fancy getting stranded.

And the price of the replacement key and socket is about £80 from Hamilton Palmer

RS2000CUSTOM · Mar 25, 2015

ORIGINAL: Waylander

Looking good, immobiliser removal is on the list of jobs to do, just don't fancy getting stranded.

And the price of the replacement key and socket is about £80 from Hamilton Palmer

As I am off to Dinslaken Apr/May I am so relieved that it failed whilst in my workshop

Must admit it was originally installed very neatly and my car still has its Porsche alarm fitted

Waylander · Mar 25, 2015

Forgot to add that's a nice bit of welding, no newbie did that

RS2000CUSTOM · Mar 25, 2015

ORIGINAL: Waylander

Forgot to add that's a nice bit of welding, no newbie did that

Well I certainly didnt do it - lol

My friendly engineer can also weld !

RS2000CUSTOM · Mar 26, 2015

Today I got the casings ready for powder coating

and what a great end result

Have ordered some Bilstein decals to finish the job off

ALZ 1933 · Mar 26, 2015

Looking very nice, excellent pictures showing others how it should be done!

RS2000CUSTOM · Mar 26, 2015

ORIGINAL: ALZ 1933

Looking very nice, excellent pictures showing others how it should be done!

Thanks for the comments

Cant wait to get them fitted and try out the new front and rear suspension

RS2000CUSTOM · Mar 28, 2015

So today I removed and stripped my original struts

Both struts had no damping effect at all and only a small amount of rebound - so officially scrap !

They also had a lot of movement at the top of the strut casing which was felt through the car over rough roads

My new struts should look great once fitted

Also I am now getting together a nice little collection of "special" tools

The last one is a tool I have had made to tighten the front shock insert retaining nut

MartinRS2K · Mar 29, 2015

Excellent work Dave, they look superb [

]

RS2000CUSTOM · Mar 30, 2015

ORIGINAL: MartinRS2K

Excellent work Dave, they look superb []

cheeRS Martin

Done a bit more today on the upper spring cup and top mount

Waylander · Mar 30, 2015

I would have bought new ones for the cost... (spring cups)

951 343 528 00 £10.73 inc vat Each

RS2000CUSTOM · Mar 30, 2015

ORIGINAL: Waylander

I would have bought new ones for the cost... (spring cups)

951 343 528 00 £10.73 inc vat

I like a challenge - lol

but to be fair I will see how they look after powder coating and £10 each is a sensible idea

RS2000CUSTOM · May 4, 2015

Well it has certainly been a while

Have just got back from a great trip away to Dinslaken Porsche Show

The new suspension was - AWESOME

Waylander · May 4, 2015

Dave are you going to sell the collars or even do a conversion service, there are two guys on the 968 forum asking

RS2000CUSTOM · May 4, 2015

Waylander

I will be offering an exchange service soon and will be selling collars on their own for the more enthusiastic DIY'er or for people in foreign lands to keep p&p low

My engineer has been on a 3 week jolly and I hope to start getting collars v.soon now he back