[Shotimes] Update on Koni in Tokico rear housing

Fri, 16 Dec 2005 12:19:11 -0600

Good grief Zach.  Can't you run down to AutoZone and pick up a couple
aftermarket struts for $50 or so and just use those housings?  Sounds like
it would save you weeks of work!

Dave

-----Original Message-----
From: shotimes-admin@autox.team.net [mailto:shotimes-admin@autox.team.net]
On Behalf Of Zach Leahy
Sent: Friday, December 16, 2005 12:09 PM
To: Sholist
Subject: [Shotimes] Update on Koni in Tokico rear housing

I have been busy lately, but got to working on the Koni in the rear Tokico
housing install some more last night.

Background:  Fitting Koni rear inserts (shorter version) into Tokico rear
housings.  Old Tokico's exploded oil everywhere.  car has and will retain
eibach springs.

I had a very hard time removing the screwed in retainers that held the
tokico cartridges in places, and eventually took a rotary cutter and sliced
the top 1/4" off the housing and slid the cartridge out.  They are threaded,
but mine just would not budge even with significant heating.

So I got the cartridge out with the housing cut back about 1/4" and then
took them back to my house (had to cut the stuff at my brothers a few miles
away).  I dropped the Koni cartridge into the Tokico housing and found that
it was close, but needs some more modification.  The top of the Koni sits
about 1" out of the top of the housing, as it has some little catches that
are designed to an OEM housing.  If you look at the bottom though, it is
about 1 1/2 to 2" from the bottom of the housing.  Comparing the two
inserts, the Tokico is slightly longer than the Koni.

The plan now is to measure on an unmodified Tokico the length from the
spring perch to its max extension at the seat for the nut.  Then modify the
housing to match that.  Any remaining gap in the bottom will be filled in by
an section of heavy aluminum tube.  Since the overall height of the spring
from the perch determines the amount of travel available, I am trying to
match that up as best as possible.  If the height of the strut is too long,
the spring will be loose and possible pop out of f it's seat.  If it is too
short you loose some of the characteristics of a progressive rate spring,
the rear would be firmer since the spring is already preloaded to a higher
degree.

I will look closer at it tonight, I may have to grind off the little catches
on the Koni insert but would like to avoid that as it would likely void any
warranty on them.  They are just a little bubble in the outer housing that
acts as a seat.  Also, the rubber rings provided on the Koni's will not fit
in the housings, but the top of the strut is tight.  If you draw them down a
bit with the bolt then it will make a very nice and snug fit on the top so
there will be no radial play at all.  I suspect there is a slight taper on
the Koni inserts just for this reason.  I will investigate.

When all is finished, I will measure the total mount to mount length on an
assembled Tokico and then replicate that on the Koni setup as you will
likely need to adjust how deep into the spindle the Koni sits, which will
change the ride height.