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Old 06-20-2003, 07:51 PM   #1
BlackEye
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Member#: 36203
Join Date: May 2003
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2003 WRX
Platinum Silver Met.

Default Installing Koni Inserts...

Has anybody here installed their own Koni inserts? Aparently you have to cut off the top of the strut housing and pull out the factory insert on the SOA struts, then press in the new insert.

This all sounds kinda hairy, have any of you tried it?

Or, do any of you know of any instruction sites for it. I was going to buy the inserts off Tirerack but I wanted to check with all of you first.

Russ
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Old 06-20-2003, 11:23 PM   #2
teiva-boy
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Old 06-21-2003, 11:06 AM   #3
OddMonkey
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I did mine, and it wasn't nearly as bad as i thought.

Some notes:

Make sure to measure your cut off points carefully; if you cut too far down the strut body you get a nice door stop instead of a strut.

You have to drill a large hole in the bottom of the tube. It says 14mm in the instructions, but I looked everywhere for a 14mm bit and wound up using a 9/16 and it worked just fine.

I also could not find a 1/2 drive 7mm allen wrench to torque the inserts to the tube, so I used some loctite and tightened them to the "very firm" level

The torque specs on the three top bolts is like 14.5 ft/lbs, so be carefull when you reinstall.

Get an enormous breaker bar and a couple/three 19mm sockets to get the front suspension parts off. No joke on on this one. I used the handle for my floor jack, and though I was gonna get the car off the jackstands before it popped free.

I picked up a GearRatchet from Sears, and that made removing the top hats from the old struts really easy. It also came in usefull for a front sway bar install.

Thats all I can think of for now, let me know if you have any other questions. It *is* worth the effort
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Old 06-21-2003, 11:13 AM   #4
BlackEye
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Default THANKS!!!!!!!!

Awsome link, thanks...
Russ
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Old 06-21-2003, 12:01 PM   #5
teiva-boy
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If you need any special tools, Harbor Freight has em.

I got my 7mm allen wrench set(3/8th") Works great on my torque wrench

You dont need to have a 14mm drill bit. You can use a smaller one and ream(sp?) the crap out of it to get to the desired size. I did this.


As for cutting of the top, you dont have to measure anything. You can cut it 1" too much and it'll still work. It gets bolted down from the bottom, so the top side cut is irrelavent. Just cut it as close to the top weld as possible.
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Old 06-21-2003, 01:40 PM   #6
OddMonkey
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Quote:
Originally posted by teiva-boy
As for cutting of the top, you dont have to measure anything. You can cut it 1" too much and it'll still work. It gets bolted down from the bottom, so the top side cut is irrelavent.
On mine the inserts fit kinda loose, up to the point where there were raised ridges that held it in place as I tightened the allen bolt, YMMV.

Quote:
Just cut it as close to the top weld as possible.
Yep. I think even with measuring thats the way mine turned out. It was the first "real" work I had done to the car, so I was paranoid about screwing it up
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Old 06-21-2003, 01:55 PM   #7
Chuck H
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I'm still in the planning stages of my suspension upgrades. Previously I had all but made up my mind to go with the dealer SPT spring/strut package. But these Koni inserts sound like an attractive cheaper alternative.

The only experience I have with Konis is that they are factory equipped on my ACR Neon, and they make a HUGE difference in the handling of that car. Can anyone compare the WRX Koni inserts to the SPT suspension setup as far as handling? Also, what springs is everyone using with them? I tried Eibach Prokits on my Neon and wasn't impressed. I'd prefer a linear rate spring to a progressive one if there are any good options available.

Thanks in advance for any insight.
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Old 06-22-2003, 09:17 AM   #8
sdecker
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Blackeye:

PM Steve_D if need further install help. He did mine for me and claimed it was very simple.

Chuck H:

Consider using the Prodrive springs -- they are linear and roughly 10-15 percent stiffer than stock. When combined with the Konis I dropped 3 seconds a lap at Road Atlanta. That's *huge*, but you probably already know that.

I can't compare to the SPT stuff, but the Prodrive/Koni combo works great. Go here for more info: http://forums.nasioc.com/forums/show...=koni+prodrive

GTguy (Kevin) can probably give you more feedback on the SPT stuff as well.

Good luck,

Scott
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Old 06-26-2003, 09:44 PM   #9
Gonz
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I'm installing the Koni shock cartrdiges on Sunday. The only real concern I have is about where to cut.

I saw the post about " cut as close to the top weld as possible"

I haven't looked at the strut carefully (without the dust cover) since helping someone put springs on a while back...

The strut has a gold cap on the top. I think, but am not sure if this cap can be popped off. The reason I think that is can be is because the instruction for my ground control spring sleeves say " NOTE: knock off gold cap to install coil-over hardware, then re-install gold cap"

So the question is are you guys cutting just below the Gold cap, or removing the gold cap and cutting just below the top end of the strut housing ??

G
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Old 06-26-2003, 10:53 PM   #10
OddMonkey
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below the gold caps... here is where I cut mine:



you can probably cut them closer to the tops than I did, but that worked perfect for me.

now I'm trying to figure out why I still have the things :/
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