BMW E30 Bilstein front strut insert - bump stop length, working with swaged end nut

#BMW #E30 #Bilstein #FCMElite

Note: the chromed shaft diameter is 11mm (not 10mm as I mentioned in the video). Finally finished the FCM Elite Stage 2 optimization for Steve's BMW E30 front strut inserts (rears completed and delivered before Christmas). Getting the swaged end nut off took some ingenuity, then machining to turn new threads and make a custom M10 washer to go under the new end nut. Always something new to learn!

I used a 32mm 'nose' section of a Bilstein 'medium' (yellow-colored) bump stop, plus an 8mm Delrin packer. The original Bilstein B8 bump stop was 80mm and had begun to degrade due to the constant bump stop contact. So, based on research provided by other forums, going to the 32mm+8mm combo will give additional free travel at static height (using Dinan lowering springs) plus sufficient protection during moderate and full compression events.

Note that there are TWO different end nuts and the correct one depends on the type of strut insert you're using.

34-003350 (50mm tube OD) uses end nut p/n E4-SB7-Z004A00 (41mm nut OD)

34-003343 (46mm tube OD) uses end nut p/n E4-SB7-Z004A01 (36mm nut OD)

https://clickableautomotive.com.au/news/BMW-E30-strut-size/

"you’ve ever decided to replace the struts on your E30 3 Series, you’ll know that there’s a frustrating amount of conflicting information on strut sizes. The BMW E30 was designed with a strut housing that held shock absorber inserts, rather than the shock mounting directly to the chassis at the top and to the suspension arm at the bottom. These strut housings came in two sizes: 45mm and 51mm. Knowing which size your car came with is important when buying strut inserts. So how do you find out what your E30 has?"

https://s14net.vbulletin.net/forum/s14/general-e30-m3-discussion/1220203-should-new-bilstein-sports-feel-this-still/page4

Thanks to the BMW online community for providing info and feedback on this topic. I hope this video is also useful/helpful for future modifications.