Strut tower opening enlarging

Discussion in 'Suspension and Chassis' started by strengthrehab, Jul 8, 2018.

  1. strengthrehab

    strengthrehab TMO Race

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    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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  2. VoodooBoss

    VoodooBoss Rick Moderator

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

    The_Dead_Cow Mike

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    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).
     
  4. gtorpedo

    gtorpedo TMO Advanced

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    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.
    IMG_1375.jpg IMG_1202.jpg IMG_1200.jpg
     
  5. TMSBOSS

    TMSBOSS TMO Addict

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

    gtorpedo TMO Advanced

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    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.
     
  7. strengthrehab

    strengthrehab TMO Race

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

    Take a while to cut through?

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  8. gtorpedo

    gtorpedo TMO Advanced

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

    strengthrehab TMO Race

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    Planned on using wd40.

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  10. strengthrehab

    strengthrehab TMO Race

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    @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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  11. gtorpedo

    gtorpedo TMO Advanced

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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.
     
  12. strengthrehab

    strengthrehab TMO Race

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    Perfect. Thanks sir.

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  13. VoodooBoss

    VoodooBoss Rick Moderator

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    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
     
  14. strengthrehab

    strengthrehab TMO Race

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    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. [​IMG]

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  15. TMSBOSS

    TMSBOSS TMO Addict

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    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.:rolleyes:
     
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  16. TMSBOSS

    TMSBOSS TMO Addict

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    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.
     
  17. strengthrehab

    strengthrehab TMO Race

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    Yes someone on the fb page did it that way.

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  18. Grant 302

    Grant 302 OPM Spent: $587,402 Moderator

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    It's a concern. Not a big one IMO in the two pics above.
    I dunno what you mean. :D;)

    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.
    [​IMG]

    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.
     
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  19. VoodooBoss

    VoodooBoss Rick Moderator

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    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.

    08D377B3-A47E-4BE2-94E8-FDCACB193610.jpeg
     
  20. strengthrehab

    strengthrehab TMO Race

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    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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