Cutting Down Strut Inserts

RexRod · 11-08-2009, 11:53 AM

Hello all,

I know this is going to sound crazy to most of you, but I'm hunting for some very used KYB AGX 765015 front strut cartridges. These are for the 91-95 MR2.

I want to cut them up for an experiment, and I just don't have the heart to butcher good ones. So if anyone has a used-up set lying around, I would really like to get my hands on them. I would of course be willing to pay shipping and something for your time.

What I'm going to do with them is cut down the bodies and stems so the whole assembly ends up being approximately 1.5" shorter. I'll first machine the tops off the bodies, and disassemble them. Cut the bodies and the stems/shafts down 1.5" shorter. Then machine and tig weld on a new threaded socket and top so I can get them back together. I'll even put a flush schrader valve in the bottom so I can charge them back up. If what I'm trying to do works, then I'll go ahead and buy a new set to do the same thing to. I'm not after being able to make them re-buildable, just shorter.

If something like this turns out to be interesting to others, I would be happy to do a full writeup of my experience, with lots of pictures of course.

Thanks again in advance, and sorry for such a really strange first post.

David

Sh0ty · 11-08-2009, 12:59 PM

What are you trying to accomplish?

RexRod · 11-08-2009, 02:36 PM

I was afraid someone would ask that question.

I hope the MR2 community knows how darn lucky they are to have solid and good aftermarket support from the motorsports industry. Where I come from, we don't.

I confess, I'm an alien from another part of the motoring galaxy.

And in our part of the universe, there is almost no performance support for our motoring endeavors.

I'm on the hunt for myself and a whole bunch of other folks, to find a front strut that can be adapted to our cars. What I've found is that the 91-95 MR2 front strut cartridge can be adapted to our knuckles with an easily machined custom sleeve. The only problem left is the length of the strut. I need to cut it down a little to make it work. Not in all cases, but for the folks that are running super low.

The car in question? (Don't flame me now.....) The strut project is for the 1G/3G CRX and CIVIC, and the 1G Integra. We are really struggling to get good parts.

So I popped up my head here in the hopes other motor heads would be able to help. I figured I would just go to the source.

Take care all!

David

11-08-2009, 11:53 AM	#1 (permalink)
RexRod Creator of useful things. Join Date: Nov 2009 Location: Fort Collins, Colorado Posts: 2 Thanks: 0 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	Cutting Down Strut Inserts Hello all, I know this is going to sound crazy to most of you, but I'm hunting for some very used KYB AGX 765015 front strut cartridges. These are for the 91-95 MR2. I want to cut them up for an experiment, and I just don't have the heart to butcher good ones. So if anyone has a used-up set lying around, I would really like to get my hands on them. I would of course be willing to pay shipping and something for your time. What I'm going to do with them is cut down the bodies and stems so the whole assembly ends up being approximately 1.5" shorter. I'll first machine the tops off the bodies, and disassemble them. Cut the bodies and the stems/shafts down 1.5" shorter. Then machine and tig weld on a new threaded socket and top so I can get them back together. I'll even put a flush schrader valve in the bottom so I can charge them back up. If what I'm trying to do works, then I'll go ahead and buy a new set to do the same thing to. I'm not after being able to make them re-buildable, just shorter. If something like this turns out to be interesting to others, I would be happy to do a full writeup of my experience, with lots of pictures of course. Thanks again in advance, and sorry for such a really strange first post. David

11-08-2009, 02:36 PM	#3 (permalink)
RexRod Creator of useful things. Join Date: Nov 2009 Location: Fort Collins, Colorado Posts: 2 Thanks: 0 Thanked 0 Times in 0 Posts iTrader Rating: (0/0% )	I was afraid someone would ask that question. I hope the MR2 community knows how darn lucky they are to have solid and good aftermarket support from the motorsports industry. Where I come from, we don't. I confess, I'm an alien from another part of the motoring galaxy. And in our part of the universe, there is almost no performance support for our motoring endeavors. I'm on the hunt for myself and a whole bunch of other folks, to find a front strut that can be adapted to our cars. What I've found is that the 91-95 MR2 front strut cartridge can be adapted to our knuckles with an easily machined custom sleeve. The only problem left is the length of the strut. I need to cut it down a little to make it work. Not in all cases, but for the folks that are running super low. The car in question? (Don't flame me now.....) The strut project is for the 1G/3G CRX and CIVIC, and the 1G Integra. We are really struggling to get good parts. So I popped up my head here in the hopes other motor heads would be able to help. I figured I would just go to the source. Take care all! David Last edited by RexRod; 11-08-2009 at 02:41 PM.. Reason: Fixed typo

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11-08-2009, 12:59 PM	#2 (permalink)
Sh0ty Armchair Racer Join Date: Aug 2008 Location: Novi, MI Posts: 678 Thanks: 17 Thanked 33 Times in 32 Posts My Google Map iTrader Rating: (3/100% )	What are you trying to accomplish?