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MR2 Strut insert conversion (with airbags)


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OK, did just a TINY bit of work on these today....

 

 

I made THEE CUT on one of the front struts, and looks looks like the 63mm is just about the perfect amount

 

Fronts, side by side

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6144.jpg

 

inserted

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6145.jpg

 

clearance to the top

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6146.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6147.jpg

 

Derek

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I'm just gonna use 2 1/4" exhaust tubing to sleeve it. I have artinist's coilover sleeves, and they're not tight against the strut body, so that'll make it a tighter fit. not exactly sure what I'm gonna do for the new "perch" yet

 

I tried getting some of the header flanges AndyW used, but can't find them local (other than a speed shop I haven't gone to yet)

 

where I cut mine, the "weld" will be 2.5 " from the perch on the fronts, and 2" on the rear. right in the middle of the coilover sleeve

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well, got another package today, 101propose helped me out with the nut for the camber plates. for the plates he makes for RX7's and Porsche's, he already has the nuts that will fit the MR2 inserts and fit right onto the Starion plates.

 

New, left. Stock, right

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6149.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6150.jpg

 

 

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6148.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6151.jpg

 

Thank you Mookeeh

 

Derek

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man.... that mookeeh is such a cancer to this site. [/sarcasm]

 

looking good. when are you going to start selling direct replacement Illumina strut asy's? ;)

Edited by Sully
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OK, got the other front strut cut down today (was gonna change the headgasket on my car, but the one I have laying around is the 8770, I want the 9116, ugh)

 

I'm actually using a pipe cutter to make the cuts where it can, it's smoother than what I could do with the cutoff wheel.

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6167.jpg

 

As you can see, these had some dirt built up in the perch, I'm giving them new life, hehe

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6169.jpg

 

both cut fronts, sitting next to a still uncut rear SHP. as you can see, they're now shorter than a stock rear strut, hehe

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6170.jpg

 

And I'm including this pic of the cut outs as well. I got a pm from someone telling me I could have just cut the tops off, and re-threaded them. WELL, I don't have the $100 tap, or the know-how to machine them in (probably even harder to do on the fronts with the hub being part of it) This pic also shows WHY I cut out where I did, there was some massive pitting just above the spring perch from dirt collecting in there for the 9 years of being on my parts car with no front fenders, and who know what from before I got it.

 

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6171.jpg

 

Derek

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SO, I got some more work done on these today, I wanted to get all the cutting done before I go back to MN, might stop by a local place tomorrow, and see about getting them welded together. Perches and sleeves will have to wait till I get the rings to use as perches in.

 

ANYWAY, rear strut cutting time...

 

just getting the last tiny bit of the stock perch off

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6172.jpg

 

Cut 53mm, and with the Tokico Illumina inserted

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6174.jpg

 

about 1mm from the top edge (about 1mm too much cut, but it's not a huge deal)

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6173.jpg

 

Went ahead and cut a piece of the 2 1/4" OD exhaust tubing to 110mm to use as a sleeve

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6176.jpg

 

Other side (I'll use a smaller length of the exhaust tube to "cap" off the hole left where the adjustment knob was, it'll make for a cleaner appearance)

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6177.jpg

 

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6178.jpg

 

Earlier today, before I cut the last one

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6180.jpg

 

ALL 4 of the pieces cut out from the struts

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6185.jpg

 

All 4 struts, at cut length, ready to be welded, two with sleeves slipped over

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6181.jpg

 

Derek

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I "tacked" each one together in 4 spots (a little more than a tack though, don't have, it's my first time welding, hehe) to hold them together, then ground them down smooth

 

Also gave an attempt at welding some of that exhaust tubing over the SHP adjustment knob hole, it on, but it's not sealed, or pretty, I'll take car of that later

 

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6187.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6190.jpg

 

Derek

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ok, cut the sleeve back off the one because it looked like crap, and decide to paint one of them, to see if I liked how it looked in grabber green, hehe.

 

OH, and a few close ups of my "tacks"

 

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6192.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6194.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6195.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6193.jpg

http://www.26liter.us/gallery/albums/userpics/10030/DSCF6191.jpg

 

Derek

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I've noticed that Derek takes his time and does it right. Unlike most of us that get anxious and throw s*** together.

It may be a while. Also considering he's going back to WI soon.

 

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I've noticed that Derek takes his time and does it right. Unlike most of us that get anxious and throw s*** together.

 

+1

 

His documentation is awesome too. This seems like a fairly straight forward mod from what I can see, just gotta be precise.

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