Koni install on a 1g with KYB GR2 casings

[Ludachris]

So I've cut up the casing and am test fitting the Koni insert into the old GR2 casing. The bottom of the Koni insert doesn't quite reach the bottom of the casing. In fact, it's enough of a distance that the bolt that comes with the Koni kit doesn't even come close to catching the threads. My options are to A. get longer bolts that will catch the threads, or B. cut the casing shorter.

If I buy longer bolts, it doesn't seem to me that the setup would be all that strong. It would seem stronger if I cut the casing and allowed the insert to sit at the bottom of the casing tightly. However, if I cut the casing shorter, I'm not sure what negative effects it will have.

Can anyone chime in on this?

 

[stirpicult]

got any pics?

 

[Mike1992]

I vote for cutting the casing shorter

 

[Ludachris]

So here's what I did - I went and bought longer bolts at a local hardware shop (one that specializes in fasteners). As you tighten the bolts it essentially "presses" the Koni insert into the casing by pulling it down. The little ridges on the Koni insert are forced down into the narrower part of the casing and it fits tight. Once the longer bolts pulled the insert down far enough to where the original bolts would catch, I swapped them out for a tight fit. Problem solved, not additional cutting necessary.

The one problem I'm having now is getting the upper perch to sit down on the Koni shaft. It doesn't seem to fit right - the shaft seems thicker than the old one.

 

[suicidal2af]

So here's what I did - I went and bought longer bolts at a local hardware shop (one that specializes in fasteners). As you tighten the bolts it essentially "presses" the Koni insert into the casing by pulling it down. The little ridges on the Koni insert are forced down into the narrower part of the casing and it fits tight. Once the longer bolts pulled the insert down far enough to where the original bolts would catch, I swapped them out for a tight fit. Problem solved, not additional cutting necessary.

The one problem I'm having now is getting the upper perch to sit down on the Koni shaft. It doesn't seem to fit right - the shaft seems thicker than the old one.

Konis have thicker shafts than KYB's. I'm running AGX's right now, but am considering swapping my fronts for Koni Yellows. I've got GC's, so I called to get some pricing on the inserts for the Koni perch and other ancillary items that would be needed. Besides needing that piece, they said I'd also need to bore out the hole in the upper perch to 12mm, I believe it was.

Your stock stuff will fit on the GR2's because, well, KYB makes our stock stuff. GR2's for us are basically our OEM shocks.

 

[Ludachris]

It actually fit over the shaft after all, a little snug, but I got it on. Maybe the 2g install is different?

 

[boostedinaz]

I have a question about this same subject as well so I thought I would bring this back as I had no luck searching.

Can I use an AGX "shell" for this conversion or does it have to be a stock KYB "shell"? I tossed my stockers a year ago when I went with AGX's but now I want Yellow's for more travel but didn't know if I could use the AGX "shell".

 

[Ludachris]

If I had my AGX's, I would have used them. I don't remember seeing anything that said you couldn't.

 

[project_tsi]

Old thread, but yes you can use AGX shells, I just did it tonight. Luckily my AGX's were blown so I didn't feel all that bad hacking them up. Damn things though, I tried cleaning them up with brake clean and it stripped the paint! So I took it all off and gave them a quick coat of black.

 

[project_tsi]

Oh and instead of buying new bolts to draw the koni's into the shell you can just tap in on the ground a few times until it slides all the way into the shell, then bolt it up.