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Thread: Help with Koni Race Strut Build

  1. #1

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    Default Help with Koni Race Strut Build

    My WRL endurance race team decided to jump off the cliff and build some nice coilover struts for our BG chassis (2000 Escort ZX2). Originally we were looking at working with some VW Sport inserts or Honda inserts, but after talking with Koni tech, we jumped on the Koni single adjustable Race Inserts. Anyway, we did our homework for the Sport inserts, but failed to realize the Race inserts are 1.5mm larger in diameter. Our front housings are not a problem, but the rear strut housings (tokico brand) have basically the same ID as the insert OD, so just doesn't fit inside.

    We are considering swaging the ID, but would prefer to simply find an alternate rear strut that may have a slightly larger housing. Based on our measurements, the fronts are 2.005" in OD. The rears are coming in at 1.915" OD or about 2.5mm smaller than the front. My question is, does anyone know if any other brand of rear insert has a larger OD (and thus ID)? Perhaps, someone has some busted struts laying around they can measure. Maybe a different platform or application? Only thing we are reusing is the tube and the spindle bracket, everything else is getting removed.

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    I will try to remember to measure tonight.
    00' Black S/R - s252 bullseye, spa manifold, turbosmart wastegate, turboXs bov, ms3x, mtx-75 transmission, bilstein coilovers
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