There aren't really very many Bilstein inserts to even choose from. If you search around in the part number system, it gets to be fairly straight forward to picking out the inserts. From there, you can call Bilstein and they will give you extended and collapsed lengths along with body length. The 36mm stuff I believe all uses the same size tubes on the inserts so it will be 1.81" OD. They also have some 30mm inserts, but I'd rather have the larger load bearing tube of the 36mm. Bilstein also released unfinished 46mm struts this year for rally applications. These are likely what I'll use on my EVO setup.
Another option would be shortening the body and shaft on the E36 Sports, removing the spring perch and cutting the body for a circlip. This is something that you could likely just pay them to do and it likely adds about $150 per shock. Now you are close to $400 a strut though.
I considered using something like the E30 gland nut but the press in sleeve will hopefully work out well. The issue I would have however is that it will never come apart now. Just for good measure, I added some JB weld in a couple strategic places to ensure it is rock solid.
I did design the sleeve in such a way that I can remove the linear bearings though in the future and will be able to rebuild the entire strut if needed.
I meant to assemble everything without the spring installed and see just how much of the travel I can use before stuff starts running into each other. I'm thinking I will likely have at least 1" of the upper shaft that will not be used though. If so, I'll likely modify the strut insert with a shrader valve to make it rebuildable in the future. I'm betting I have it back apart and add a helper spring and a shorter main spring within the year though. I'm thinking it likely would be low enough for my wants after I modify the spindles.
Last edited by 03whitegsr; 08-28-2013 at 10:45 PM. | 
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