Yea, this project took another turn
It went from me wanting to valve them, then wanting to send them to bilstein, then having someone else valve them, then me valving them.

I just ordered the two remaining tools needed to start the job. I'm hoping for some help to at least be close the first time but it's not looking good.

 

This part of my koni build has been the most frustrating. I have not found a way to mate my upper spring perch to the bearing. Right now I am using three 1/2 inch washers as spacers to gain enough clearance so the spring perch does not contact the top mount.

I did the same thing with the stock top mounts with the bearing cup, but I bet my bearing cup sits higher than yours does and therefore I have to clear more room vertically than you do.

 

Thanks for the props. The upper spring perch can't move around because it is concentrically mated by the small spacer at the necked portion of the damper shaft...if that makes sense. I'm planning to avoid potential galling between the upper perch and the small spacer by applying a spray-on PTFE coating to the inside surface of the small hole. The design is based on a set of ZZyZX STi coilovers that I spent some time rebuilding for a fellow auto-xer. Mac, when you see how the assembly goes together, all doubts will be removed.

Robinson, I had the same problem with a set of Koni coilovers for my 1990 VW Corrado...to what sounds like a lesser extent, but similar. I ended up using a washer to get the space, as well.

 

Cool, looks like you have it covered bummer you live so far.

I test drove a Corrado when they first came out and going from a 79 Scirocco with some Sachs struts, KYB shocks, ST springs and sway bars I got from a junkyard. Driving the Corrado was like a dream.

 

So I take it that when fully compressed the shaft isnt at the bottom of the body? Otherwise wouldn't you be getting into a bottom out situation?
Do you plan on running bumpstops?

 

Correct, there is enough room to shorten the bodies and avoid bottoming the piston/shaft assembly. The front dampers are very long and the rears are just long enough to handle the shortening. Bump stops will be used front and rear.

 

nmrado, are you running the bilstein digressive pistons or something else?

 

I asked for digressive/digressive valving, but I left it up to the damper builder in the end. I haven't had a chance to talk to him since I shipped my Bilsteins to him.

 

Definitely curious to know what he decides on.

 

cant wait to see both of your suspension setups when all is said and done. Looks like im gonna go the pss route and do some more homework.