Shortening struts

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If you lower your car very much, the strut will start bottoming out. To mitigate this, shorten the strut. It's easy and can be done with or without welding.

Overview

1. Cut tube in section. Don't cut towards the top as you need to preserve the internal tube threads for the strut gland nut
2. using your chosen short insert, shorten the tube to suit
3. leaving old inserts in the strut (covered in a smear of oil) stitch weld the tube back and grind back to the diameter. don't let it get too hot or you'll have an oil fire.

Additionally, you may choose to re-position the lower spring seat (or coilover adjustable sleeve) in a way that the leaves enough clearance for tyres.

Remove Spring Perch

Use a handheld grinder or a bench grinder. Be careful not to cut through the stut tube.

Overview

Remove the strut/spring/brake assembly, then remove the spring and the strut shaft/insert.

Grind the lower spring perch free from the strut tube.

Cut the strut to the length you want. For a three-inch lowering job, cut the strut three inches.

Then place the spring perch where you want it and fasten securely. You can have it re-welded or use a commercial-grade shaft collar.

Cutting Strut Tube

Can a cheap tube cutter do the job? A pipe cutter might work but they're actually quite thick walled tubing so it might take a bit!

A good old drop saw (chop saw) does the trick on the tubes. It will hold the tube perfectly square and just cut it through (after removing the strut piston/insert of course).

Cut down, spring perch welds ground off

Ready to prime (use weld through primer to seal under where the spring seat will go)

Primed, now ready for fastening the spring seat

Fasten Lower Spring Seat

You can place the spring perch where you want it and fasten securely. You can have it re-welded or use a commercial-grade shaft collar.

See main article: Fastening Spring Seats