New Koni Sport front struts for your car
2 #20134 5" coil over sleeve
2 #20133 Adjustable nut lower seat from Afco
2 #23550 10"x 550# springs from Afco
This guide will walk you through building your own Koni coilovers for about 500 dollars. Koni struts have a smaller body diameter so they will accept standard " large body" coil over sleeves.
Starting with a new Koni sport adjustable shock, cut a slice in the lower spring seat. Cut it on the side that has the small hole in it. I used a chop saw, but a hack saw (etc) will work also. Cut right up to the little hole.
Using a small disc grinder, grind a shallow grove around the seat just under the weld. Don't go too deep or you will score the actual strut body! You are not trying to cut all the way through the seat!
Now using a small sharp chisel connect the grove to the small hole in the spring seat. Don't chisel straight into the strut, you don't want to dent the body! Chisel in a downward direction.
Hammer up and down (gently but firmly) on one edge of the seat until your grove starts to crack. Continue hammering around the seat until it is loose.
Using a pair of channel locks or vice grips etc., twist and deform the loose seat enough to open up the hole so it will slide up and off.
Using your angle grinder, grind the weld down to a height that is just small enough to let the coilover sleeve slide over it. Now spray paint over the raw metal to prevent rust.
Test fit the sleeve on the strut. The sleeve should sit on top of the sway link bracket.
Now to make the upper spring seat and to modify the stock upper spring seat. Using 1/4" thick 6061 alum plate cut out a 3.5" disk and a 2.5" disk.
Hold the stock with plyers while using to drill to avoid injury.
Next drill out the centers the same size as the shock shaft size. Slide the two discs over the shaft and clamp them together, remove them and drill two holes. Pop rivet the two pieces together. Then slide everything back onto the shock for another test fit.
Now take the stock upper perch and trim it down to about 3.5" diam.
When cleaned up it should look like this.
Screw the new lower spring seat down the sleeve. They have a set screw with a plastic tip on it for locking the seat in place.
Using a razor take your stock strut bump stop and cut it in half, saving the top part.
Then slide the modified bump stop on the shaft,
then the spring and upper seat,
then the modified stock upper seat and the rest of the stock hardware.
Congratulations. For about 500 dollars you have just built yourself a set of Koni coilovers.