Thought I'd let everyone know that installing modifying the stock front struts to accept the Koni inserts is NOT HARD AT ALL.

I used a hacksaw to cut the top of the stock struts and, although not the quickest thing, was fairly easy. I used a new blade for each strut. I didn't need to drill the pressure relief hole at the bottom, either; it wasn't necessary. I just cut through the top of the strut until I broke through. The pressure was relieved just fine that way (very little pressure inside). I made my cut *right* below the tabs for the pressed-on top cap. This is important; had I cut 1/4" further down the body I would have messed up some locating tabs inside the stock strut housing that the Koni insert uses to center itself. Also, a metal piece inside the strut is pressed into the stock housing right where I made the cut...I ended up cutting into that as well, thinking the body was just really thick...it wasn't...it's only ~1/16" thick. There's a fair amount of oil that drains out once you've broken through to the inside. Drain it all out once you can, otherwise if you continue to cut, you'll make a huge mess (oil flinging everywhere). I used a uni-bit to drill the bottom hole and stopped at 5/8"; turned out to be the perfect size.

Total time to do both front struts: 2 hours (~1h15m for 1st one, 45m for the other).

Also important to note is that the overall finished assemblies seem very solid and sturdy. Certainly doesn't seem cheesy or hacked up or anything. The bolt and washer for the bottom of the strut (that holds the insert in place) are friggin massive and are definitely durable. The insert fits very tightly inside the stock housing...it actually won't go in all the way until you crank on the bottom bolt to pull it in. There's no way the insert will rattle around inside the housing. Koni even gives you some little Koni "triangle" emblems to stick onto your stock strut housing to match the rears. Looks almost like you bought the strut that way.

I would have done the install on the car but I needed a breaker bar. During the last alignment, the shop obviously used an impact wrench Also, my original dust boots are now dead...cracking/torn everywhere...so I need to buy new ones before I do the install. Next weekend...

 

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pictures from the install on someone else's car. The finished Maxima struts will look almost identical to these: http://www.vfaq.com/mods/Konis.html
the only difference is with the stock Maxima struts...they don't have a welded end cap but a pressed-fit one. But, I have a picture that someone emailed me with the cut position on an actual Maxima strut if you're interested...it just shows what I said, cutting right below the end cap tabs. Let me know if you want it emailed to you.

[Edited by Keven97SE on 08-21-2000 at 11:59 AM]

 

So how are they with H&Rs dude?

Matt P.

 

[QUOTE]Originally posted by Matt_P
So how are they with H&Rs dude?

They're not on yet...I've only installed the front cartridges...they're going on this weekend after I get the dust boots, etc. Will let everyone know my impressions after that.

[Edited by Keven97SE on 08-21-2000 at 04:26 PM]

 

I used a bench cutting machine to cut the shocks and springs, took me about 10 mins to cut the stock housing, and another 20 to drill the hole on the bottom. The rest is very easy. Also since you have not installed the shocks on the car, see the rubber black boot. seal insert with silicone and then slide the black boot on top and now you have double protection. The rubber boot in a couple of years may dryrot but you still have the silicone as added protection.

 

I think you're a little late as Keven finished his install a while back. Good information though.
-hype

 

I would add some loc-tite to the threads of the bolt holding the insert in the strut assembly. Don't ask me how, but this bolt can manage to loosen over time. Not sure if even loc-tite will help but I think it's better than nothing. I think this aspect of the KONI's is 2nd worst (just behind having to disassemble the rears shock/springs to adjust them). I periodically tighten the bolts down (~3-4 months) by turning the wheels to one side or the other and using an open-ended wrench. I definitely would have gone AGX were they available back then...

 

you can use silicone on the thrreads of the 19MM bolts they will never come loose, thats what I used. I did not post use silicone because theres someone here on the org that always seems to know more or post some stupid ****, but use silicone on the threads. Also what made one of my come loose I did not clean the inside of the stock shock and the oil that was in there loosened it up. I later took it apart and cleaned it out and tightened it and has not came loose. I removed them again when cutting my springs rechecked everything and used silicone to seal the insert and the bolts.

 

I used to have a writeup online, but it's down now. I have a pic of every step of the install if you really need to see them.