Strut tower opening enlarging

[strengthrehab]

How have people done this?

Hole saw?
Jig?
Grinder?

I know about the Vorshlag jig, but trying to dig

Anyone have details

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[VoodooBoss]

Die grinder. Mark it off with a sharpie and get busy.

 

[The_Dead_Cow]

I haven't done it myself but the jig they made for the s197 looks real nice. Using a hole saw seems like the way to go, the trick is just centering the bit. I've been pondering using a piece of wood to center the pilot bit (drill in the center of the hole saw).

 

[gtorpedo]

I just did this on my car. Get an OEM strut top mount, 2 5/8" hole saw and brass lamp nipple/tubing & nut for the pilot guide. Should run you ~$50 in materials and works great.

 

[TMSBOSS]

Gtorpedo
Does this method cut off the entire top of the tower?

 

[gtorpedo]

Gtorpedo
Does this method cut off the entire top of the tower?

No, just enlarges it by ~1/2" total. You can get more extreme if you wanted with a 3" saw. I can upload pictures of the final cut later.

 

[strengthrehab]

I just did this on my car. Get an OEM strut top mount, 2 5/8" hole saw and brass lamp nipple/tubing & nut for the pilot guide. Should run you ~$50 in materials and works great.
View attachment 4532View attachment 4533View attachment 4534

Hell yeah. Looks like exactly what I need. Thanks a ton.

Take a while to cut through?

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[gtorpedo]

Hell yeah. Looks like exactly what I need. Thanks a ton.

Take a while to cut through?

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Not too bad at all, just use plenty of cutting oil and cut gradually.

 

[strengthrehab]

Not too bad at all, just use plenty of cutting oil and cut gradually.

Planned on using wd40.

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[strengthrehab]

@gtorpedo did you disassemble the top mount or just put a hole in it big enough for the tube to go through?

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[gtorpedo]

@gtorpedo did you disassemble the top mount or just put a hole in it big enough for the tube to go through?

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No modifications needed to the top mount whatsoever, the threaded lamp tubing is the perfect diameter for the top mount and securing the pilot bit.

 

[strengthrehab]

No modifications needed to the top mount whatsoever, the threaded lamp tubing is the perfect diameter for the top mount and securing the pilot bit.

Perfect. Thanks sir.

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[VoodooBoss]

Did you make the whole hole larger? Most of the race cars cut a slot so you can move the damper adjuster over further which is the cause for the limited adjustability. I’m traveling but do an internet search.

@blacksheep-1

 

[strengthrehab]

Did you make the whole hole larger? Most of the race cars cut a slot so you can move the damper adjuster over further which is the cause for the limited adjustability. I’m traveling but do an internet search.

@blacksheep-1

The plan for me is to use the hole saw to increase the ability to adjust camber using Pedders camber plates which require a larger opening to adjust camber on the car or dropping the strut to adjust camber.

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[TMSBOSS]

Curious if any of the “Engineer Types” (Grant) can chime in on strength concerns.
Does cutting the larger hole weaken the structure of the tower more so than the elongation process?

Try to keep the answer under 2500 words and use small works for us knuckle draggers, please.

 

[TMSBOSS]

Wondering if you can have the same effect by using a piece of flat stock cut to the size of the tower then drilling holes for the bolts? You may need to ensure the mandrel is long enough to support the saw.

 

[strengthrehab]

Wondering if you can have the same effect by using a piece of flat stock cut to the size of the tower then drilling holes for the bolts? You may need to ensure the mandrel is long enough to support the saw.

Yes someone on the fb page did it that way.

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[Grant 302]

Curious if any of the “Engineer Types” (Grant) can chime in on strength concerns.
Does cutting the larger hole weaken the structure of the tower more so than the elongation process?

It's a concern. Not a big one IMO in the two pics above.

Try to keep the answer under 2500 words and use small works for us knuckle draggers, please.

I dunno what you mean.

In the S550 mount I don't see any problems opening up the hole with that saw and eliminating the two original notches.

This is about the limit of what I'd cut from the tower. Keeping the lip around the opening is a good thing. Could use some clean up.


Some seam welding a bit around the top plate to the tower wouldn't be a bad idea, but not needed.

The main thing to avoid are slots and sharp interior corners for the hole.

 

[VoodooBoss]

I’m not familiar with those CC plates but I like this idea better. Only take out what you need to get the job done. I’m not sure you’re going to get enough camber using the hole in the photo you posted.

 

[strengthrehab]

There is no adjusting camber on the car using these plates without opening up the tower in this way. Doing it the other way will not work due to the way the adjustment is done using the Allen headed screws.

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