-X- AE86 Shortening Casings -X-

Decided to do my write up on Shortening Strut casings for an AE86 SS conversion.

Tools:

Start by removing the casing from the car and removing the old most likely blown shocks/inserts.

Next the cut the perch off, this can easily be done with a plasma cutter, but any cutting tool will work. Plasma took 2 minuets for both.

Now we have to cut out how ever many MM's the casing needs to be shortened. In this case 40mm's is being removed. Its best to cut it out of the center area so it saves having to grind of the perch. It can not be removed from the top because only the top has threads to screw the gland nut back on.

Now grind each of the ends at an angle. This is important because it gives more area to weld to, rather than welding flat the casing is being welded together.

Weld the two pieces back together, please be sure to do a very good job, if this breaks this could cause loss of life, please remember that when welding, 3 inch grinder is what I used here.

Next grind the welds smooth, used a 5 inch grinder for this step.

Using a DA with 80 grit sand paper got the casing to bare metal, then using a sand blaster got the spindle areas really clean and rust free.

Now the last step depends on the person, Typically the sleeve needs to be welded on, but these are being shipped of to a person in Cali. I would normally powder coat the casings but since the sleeve still needs welded on using spray cans of Rustolem will do just fine.

*Sorry about the mess in the trunk, have to ship these off and didn't want to forget them.