Surfwagon
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- Jun 8, 2006
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My HSV Monroe struts and the Monroe GT Gas struts I cut down are exactly the same physically, size, lengths, position of brackets and height of cap (as you call it) above the spring seat.
The inserts are easy to fit, you drill a tiny 3mm hole in the centre of the base to release gas and oil, then 65mm down from the cap you saw the top off , then drill out the bottom hole to 14mm for the retaining bolt then you fit the insert inside after deburring and cleaning.
To cut the cap off, you mark it all the way around then keep turning it around as you saw through the outer skin (about 2.5-3mm thick) to get a straight cut.
You then have to figure a way of knocking the insert fully home as it has dimples near the top to keep it firmly in place once fully home then you fit the bolt and torque it up to 75nm/50ft-lbs.
BTW std HSV struts are made by Monroe and are very close in specs to GT Gas (Clubsport & R8) and Sensatrac (Senator & Grange) made for FE2 length/style springs.
The inserts are easy to fit, you drill a tiny 3mm hole in the centre of the base to release gas and oil, then 65mm down from the cap you saw the top off , then drill out the bottom hole to 14mm for the retaining bolt then you fit the insert inside after deburring and cleaning.
To cut the cap off, you mark it all the way around then keep turning it around as you saw through the outer skin (about 2.5-3mm thick) to get a straight cut.
You then have to figure a way of knocking the insert fully home as it has dimples near the top to keep it firmly in place once fully home then you fit the bolt and torque it up to 75nm/50ft-lbs.
BTW std HSV struts are made by Monroe and are very close in specs to GT Gas (Clubsport & R8) and Sensatrac (Senator & Grange) made for FE2 length/style springs.