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Thread: Help with Koni Race Strut Build

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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.
    Last edited by BryanPendleton; 09-14-2017 at 12:10 PM.

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    I will try to remember to measure tonight.
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    Jumped off the cliff a few weeks ago and plunged into this project. Originally the plan was to utilize a VW or Honda Insert-A-Strut, but after working with Koni we switched to the 8610 Race Strut Inserts.

    First step was disassembling the struts.

    Fronts:







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    Rears:






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    Front Strut Measurements:
    Body OD - 2.005"
    Body Length - 12.5"
    Shaft OD - .865"
    Shaft Length - 5.50"
    Shaft Mount Length - 15/16"
    Shaft Thread - .467" @ 20TPI
    Top Hat Mount Height - .25"
    Top Hat ID ~ .5"
    Bearing Height ~ .425"

    Rear Strut Measurements:
    Body OD - 1.915"
    Body Length - 14.625"
    Shaft OD - .785"
    Shaft Length - 8.75"
    Shaft Mount Length - 2.375"
    Shaft Thread OD - .465"
    Top Hat ID - .480"
    Top Hat Mounting Height - .715"
    Top Hat Bushing Height - 1.450"
    Last edited by BryanPendleton; 09-14-2017 at 12:10 PM.

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    Certainly a feeling of jumping off a cliff. Next race is scheduled for December at Circuit of the Americas and there is no turning back now.

    Got all the measurements and the next step was disassembly

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    First step is drill a hole in the bottom of the struts and drain the oil out.

    Next simply cut the top of the strut housing. I used a cut-off wheel on my angle grinder.

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    At this point you can pull the guts out:





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    Repeat for all for corners:



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    Just an idea, but you're going to have to check the spindle mounting dimensions first to make sure the front and rear are the same, or at least close enough that you can make compensating adjustments elsewhere.

    Grab another set of front struts and use them. Cut the spring perch off the rears and reweld them on to the front tubes at the correct location and rotation. This would be assuming the front strut extension and compression length would work.


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    Quote Originally Posted by ZX2.0 View Post
    Grab another set of front struts and use them. Cut the spring perch off the rears and reweld them on to the front tubes at the correct location and rotation. This would be assuming the front strut extension and compression length would work.
    Unfortunately the front strut housings are too short to accommodate the needed extension and compression lengths needed for the rear.

    Ultimately after we realized the larger OD of the Race Inserts would not fit, we ordered some 2" 13Ga ERW tubing. Yes it has a seam in the ID, but still comfortably fits the inserts and the ID is right at the necessary thread bore for the Gland Nut thread, after cleaning up the seam.

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    Default Help with Koni Race Strut Build

    For the inserts and gland nuts, we ordered up the following:
    Koni fronts - 8610-1436RACE
    Koni rears - 8610-1437RACE
    Koni M48x1.5 Gland nuts - 73.25.01.003.1

    Here is a photo of the inserts:

    Note that the OE strut bearing fits the shaft perfectly, though we will not need them as we are going with a universal 4-bolt top-mount camber/caster plate from Ground Control that integrates its own strut bearing.

    Note that the pillow ball hat is a Toyota Corolla AE86 hat that we had originally planned to modify to make our own custom camber plates. These will likely be repurposed for the rear struts now. The Tein hardware was perfect for the Koni struts, as the Konis come with M14x1.5 threads on the shafts.
    Last edited by BryanPendleton; 09-13-2017 at 06:48 PM.

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    Default Help with Koni Race Strut Build

    We are using Ground Control's weld-in kit, so the factory spring perches are removed in preparation for the GCs.
    Last edited by BryanPendleton; 09-14-2017 at 12:09 PM.

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    Subscribed. This is neat! I've never built a shock before and never seen anyone else make one either!

    What is the ground control kit you're using?

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    As mentioned earlier the unexpected upset was that we could not use the rear housings, and the struts we had all measured the same 1.9" OD, which simply made it too small in ID for the Koni race insert (43.5mm OD) and for a M48 gland nut. I cannot say for certain, but if you ran a Koni Sport insert (most are 42mm OD) you could probably make the rear housings work. You would need to "flare" the tops out some to put the M48 gland nut thread on.

    Once we decided to make our own, the first step was removing the OE strut bracket with as little destruction as possible. It is only held in place by a weld at the bottom of the strut housing, but removing that weld was challenging as you cannot reach it with traditional grinding tools. Ultimately we ended up slitting the backside open and cutting the bottom end off.



    Note the ~.25" loss in length and the split down the backside.

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