Front Shock Mount Frustration Options

[DennisV]

I thought I would post this to possibly save someone else frustration, or alternatively uncover something stupid I might have done.

I had a really tough time installing our new Boge front struts in the a set of new 2-piece mounts. In short, I couldn’t get enough of the strut thread above the bushing to start the nut.

It turned out it was a couple compounding issues:
1. The contour of the top portion doesn’t allow the support washer to seat as far down as original. There is a few mm gap between the washer and the metal insert.
2. When mating the top and bottom halves, even with maximum force applied, they are separated by the body which increases the total distance.

I ultimately took a Dremel to change the profile on the top in order to get the washer to sit low enough to get the nut started on the thread. Disappointing to troubleshoot and rework a new $235 part.

It is a clever design, and if I’ve done something stupid let me know. I couldn’t find another way to get the strut on.

I checked original vs new and found about 6 mm total difference in height. What was more important was the washer offset.


FWIW - I checked the strut thread length and it was the same on my old Koni and new Boge. So the strut was not the issue.