cblome@yahoo.com writes:
> Koni recommend using a drill to enlarge the 10mm hole in the dust boot
> and upper shock mount to 12mm to accommodate the larger piston rod. A
> drill bit is utterly, miserably useless for this job! It jumps around
> and makes an elliptical sort of hole, and generates so much heat that
> I trashed an expensive dust boot by melting it off its metal washer.
> Grrr! I stomped off to Home Depot and grumbled at the power tool guy,
> who politely suggested a 1/2" rasp would do the trick. Problem
> solved...the other three came out perfect. (A garden sprayer is also
> handy to keep the metal cool as you work it.) Figured I'd pass this
> tip along for the next poor sod who decides to attempt this job on
> his/her Miata.
Us BMW folks who changed to Koni externally adjustable rear shocks could have
helped you out, we've all been through this. As you noted the key is to keep
the bushing liner from overheating and water or cutting fluid is the answer.
You'll find that the 12mm drill bit works fine if you keep the rubber bushing
from overheating from the drilling friction. So don't feel bad, everyone
who's tried it for the first time without prior notice destroys at *least* one
bushing due to overheating. You'll just have to accept the fact that you're
no better than the rest of us. :-)
Same goes for the frustration, bruises, hand cuts, etc. You'll also be amazed
that after you pull them in and out several times for revalving just how quick
you'll be able to get the job done compared to the first time. As in autox
driving, prior wrenching experience lowers your time significantly. Welcome
to the wonderful world of Stock class autoxing :-).
M Sipe
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