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Old 08-03-2006, 05:54 PM   #1
SammyRex
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Default Question about koni inserts

I just recieved my koni inserts for my wagon (4 corners).
The part number for the front pair is 8610 1351Sport
The part number for the rear pair is 8610 1440sport

I am sure the rear one is for 04+ wrx. But the front pair
seems to be for the 02-03 wrx.
My question is are the 01 to 03 front koni inerts the same
as 04 to 06?
I am just wondering if I recieve the right one,
any input is deeply appreciated, thanks.


Sammy
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Old 08-03-2006, 06:29 PM   #2
SammyRex
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Never mind, I found it. They are correct.

Sammy
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Old 08-03-2006, 07:42 PM   #3
drees
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Yay, you got them! Take some pics when you cut up my struts.
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Old 08-03-2006, 07:47 PM   #4
PJC1909
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go sammy go! +1 for pics
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Old 08-04-2006, 01:09 AM   #5
SammyRex
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Quote:
Originally Posted by drees
Yay, you got them! Take some pics when you cut up my struts.
Hi Drees:

I start cutting and drilling them at 7:00 pm tonight and get them done around
12:00 AM. I have not taken any pircure yet, but will do it tomorrow.
Cutting was not hard at all, only problem is the rear struts, I only have very
little space to work on.
The thing really took me long time is the drilling, it was really PITA to do.
With hand held driller, thats the best I could do, and I finished it without
any drama.
Thanks for your struts, They are done cutting and drilling, I will post pics
tomorrow.

Sammy
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Old 08-04-2006, 01:32 AM   #6
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Quote:
Originally Posted by PJC1909
go sammy go! +1 for pics
Hi PJC1909:
I have a question to ask you. I follow the instruction to cut the struts.
I cut 40 mm from the top of the oe strut. Now, when I insert the konis,
the bottom of the koni inserts still have around 10 to 15 mm distance
from the drilled hole (the inserts stops going deeper at a point when
the side lines of the konis contact with the strut housing top edge).
Should I hammer them down to make the buttom of the inserts to contact
with the drilled hole or keep cutting the housing more until it falls right on
the hole?

Thanks for answering my question in advance.

Sammy
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Old 08-04-2006, 02:22 AM   #7
drees
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You want to use a bolt to pull them into the housing. If the supplied bolts aren't long enough, go to the hardware store and get some longer ones so that you can pull the insert into the housing.

Don't hammer them in!

-Dave
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Old 08-04-2006, 02:32 AM   #8
SammyRex
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Quote:
Originally Posted by drees
You want to use a bolt to pull them into the housing. If the supplied bolts aren't long enough, go to the hardware store and get some longer ones so that you can pull the insert into the housing.

Don't hammer them in!

-Dave
Thanks for your valuable advises .
By just seeing the cartoon provided by konis,
sometimes really dont know what they mean.
They should also provide some writen descriptions
on whats shown in the pictures.

thanks,

Sammy

Last edited by SammyRex; 08-04-2006 at 02:50 AM.
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Old 08-04-2006, 02:40 AM   #9
drees
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BTW, check this thread, it has a bunch of links w/pics on how to install Konis:

Koni Inserts, 03 WRX Wagon
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Old 08-04-2006, 02:53 AM   #10
SammyRex
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Quote:
Originally Posted by drees
BTW, check this thread, it has a bunch of links w/pics on how to install Konis:

Koni Inserts, 03 WRX Wagon
Thanks for the link. struts will be painted and tighten tomorrow, and
installed on Saturday. Review is coming soon.

cheers,

Sammy
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Old 08-04-2006, 07:30 AM   #11
PJC1909
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Looks like you figured it out.
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Old 08-04-2006, 10:27 AM   #12
SammyRex
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Here are the images of the wagon oe struts after
drilling and cutting. (struts were provided by drees, thank you)
I have not clean nor tighten them up yet. I used 1/2"
drill to drill the hole, they give me just about enough space
for the bolts to thread into the buttom of the inserts.

The front struts (easier to cut)




The drilled hole


The rear struts (more difficult to cut them due to limited space between the
spring porch and cutting line)

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Old 08-04-2006, 01:25 PM   #13
drees
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Almost there! They will look like new after a fresh coat of paint. Powdercoating would be awesome, too.
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Old 08-04-2006, 01:34 PM   #14
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I thought those little nibs had to go inside the housing to center it or something?? I'm trying mine this weekend.

and how the heck did you cut the rears?
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Old 08-04-2006, 03:04 PM   #15
Nargaredama
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What springs will you be using?
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Old 08-04-2006, 03:04 PM   #16
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wagon specific USDM pinks
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Old 08-04-2006, 03:18 PM   #17
Nargaredama
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I'm thinking of getting the Koni's for my wagon and am curious how well they work with stock springs.

Can anyone chime in?
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Old 08-04-2006, 03:36 PM   #18
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Quote:
Originally Posted by infantsam
I thought those little nibs had to go inside the housing to center it or something?? I'm trying mine this weekend.

and how the heck did you cut the rears?

Yep, I did mine 2 weeks ago and that how it worked. After cutting the OEM strut, I inserted the Koni insert. The nibs hit the OEM strut wall and would not go in any further. The Koni cartoon, I mean instructions, seem to show hammering on the tops of the struts to get the nibs inside. I didn't like that idea. Others have talked about getting a longer bolt. I looked at a couple of hardware stores but could not find a longer version of the botton bolt that Koni provided. Other NASIOC posts said that you can use the bottom bolt without the concave washer or the lock washer and get it to grab the insert. I did this and it worked great. I pulled it down a little with no washer and then put the washers on and pulled it the rest of the way.

I used a pipe cutter to cut the front (easy) and used a dremel to cut the rear (not so easy).
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Old 08-04-2006, 04:53 PM   #19
bWRX
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Can I threadjack a little and ask people reading this thread what kindsa powertools might be good to have to build koni struts?
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Old 08-04-2006, 06:01 PM   #20
SammyRex
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Quote:
Originally Posted by infantsam
I thought those little nibs had to go inside the housing to center it or something?? I'm trying mine this weekend.

and how the heck did you cut the rears?
I use dremel to cut both front and rear top of the struts.
The front is piece of cake, only take you about 3 minutes for both if
your hand can hold the dremel tight.
For the rear, you can cut them little bit shorter than required (with cutter
disck), then use the polisher disk to polish them until the required length
meets. But all these will not take you more than 30 minutes.
Drilling is more a problem for me, I only have a hand held electronic driller, not
the bench press type of drill. you just need lots patient to have them done.
I suggest you not to plan to finish everything in one day. Leave the installation
next day, and do them carefully.
Good luck

Sammy
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Old 08-04-2006, 06:04 PM   #21
SammyRex
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Quote:
Originally Posted by Hondo88
Yep, I did mine 2 weeks ago and that how it worked. After cutting the OEM strut, I inserted the Koni insert. The nibs hit the OEM strut wall and would not go in any further. The Koni cartoon, I mean instructions, seem to show hammering on the tops of the struts to get the nibs inside. I didn't like that idea. Others have talked about getting a longer bolt. I looked at a couple of hardware stores but could not find a longer version of the botton bolt that Koni provided. Other NASIOC posts said that you can use the bottom bolt without the concave washer or the lock washer and get it to grab the insert. I did this and it worked great. I pulled it down a little with no washer and then put the washers on and pulled it the rest of the way.

I used a pipe cutter to cut the front (easy) and used a dremel to cut the rear (not so easy).
I also have mine done the same way you did.

Sammy
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Old 08-04-2006, 06:09 PM   #22
SammyRex
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Quote:
Originally Posted by bWRX
Can I threadjack a little and ask people reading this thread what kindsa powertools might be good to have to build koni struts?
On a budget:
1. Cutting them with hand saw.
2. electronic drill for $30 in sears plus required drill bits (choose those for metal drilling)

Not on a budget:
1. dremel for cutting, around $30.
2. electronic drill, $30.


Doesnt really cost too much, but you have to be paitent to work on them.

Sammy
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