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Thread: Koni Race Insert Build

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    Koni Race Insert Build

    My WRL endurance race team decided to jump off the cliff and build some nice coilover struts for our BG chassis (2000 Escort ZX2). Originally we were looking at running some VW Sport inserts or Honda inserts, but after talking with Koni tech, we jumped on the Koni single adjustable Race Inserts. Anyway, we did our home for the Sport inserts, but failed to realize the Race inserts are 1.5mm larger in diameter. Our front housings are not a problem, but the rear strut housings (tokico brand) have basically the same ID as the insert OD, so just does fit inside.

    We are considering swaging the ID, but would prefer to simply find an alternate rear strut that may have a slightly larger housing. Based on our measurements, the fronts are 2.005" in OD. The rears are coming in at 1.915" OD or about 2.5mm smaller than the front. My question is, does anyone know if any other brand of rear insert has a larger OD (and thus ID)? Perhaps, someone has some busted struts laying around they can measure.

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    suspension mods intheworks FE3-323's Avatar
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    it might be worth custom building new strut body's for the rear, thats effectively what i did to the front on my car (bilsteins)
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    Quote Originally Posted by FE3-323 View Post
    it might be worth custom building new strut body's for the rear, thats effectively what i did to the front on my car (bilsteins)
    Yeah, that is probably where we will go. 2" 11Ga or 1/8" wall tubing would be perfect, and will just cut the spindle bracket off the old housing and weld it to the new tubing housing.

  4. #4
    suspension mods intheworks FE3-323's Avatar
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    on a fair note, i bought some seamless tube produced by ThyssenKrupp (bilsteins parent company) good quality stuff, i just wish i could remember the link i bought it from... with normal tubing the seam will screw up the fitment entirely.
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    1992- project FE3..... 313 WHP @ 9.3psi




    I pet my dash when I get into the car..."good car"
    he actually has a mazda tree, parts grow on it


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    do you have part #s for the konis

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