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Discussion Starter · #1 · (Edited)
This Thread was previously locked to preserve it's information, but has now been re-opened to help answer any questions in the future. Many of the old photos have gone, but the information is all correct still, and many of the photos do remain.

Here is the information you need to build your own Ultra-Low Fox strut housing:



This method of lowering foxes involves replacing the stock front inserts with shorter ones. The key ingredient here is VW Rabbit A1 inserts, I personally chose Bilstein Sport inserts. These should be easy to locate new for a decent price from any major retailer; if you have any issues feel free to ask me. You then need to remove a section of your strut housing to match this change, which will require cutting and welding of a key component of your car; please do so carefully!

Here is the original information that is reposted from later in this thread:
>> 46mm is the key. This will leave you a little +/- which will be absorbed by the insert nut at the top of the housing.
>> Before you cut anything, score a straight line on the housing where you will cut. This will allow you to use the line for alignment when you are welding. It's important to keep everything lined up.
>> There is +/- 1-2mm space inside the housings for penetration of welds.
>> This is all basically untested. Don't blame me when you crash / die.* Do blame me when your car is slammed on the ground and looking oh so sweeeet.

*Editing 3 years later; my suspension is still running great, but has limited miles. Several (many?) other people are now running struts modified by myself, by other people and by themselves (Dean, Jonathan, Banned etc etc), and have had good success with no reported issues. However, again this is only a guide and no-one can guarantee anything so please use your best judgement.


>> Hints for cutting and marking: Use masking tape wrapped around the housing as a guide for a nice straight cut when removing the 46mm section.
>> Really do score the body to show a straight line for keeping the steering arm at the correct angle. This angle is pretty critical - a bit can be overcome with tierods, but not a lot.
PM me if you have questions or need help.
This is what can be achieved with some coilover perches added into the mix:


Modified by the brit at 11:40 PM 9-27-2007
Original first post:
Finally, after months, if not years, of much talking and a little researching, it's started.
These are the struts, this is the arch gap. Soon one will be fixing the other.


More photos when i start work tonight.



Modified by the brit at 3:05 PM 9-12-2008
 

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Discussion Starter · #2 ·
Re: The End of the High is Nigh! Say good to two inches. (Banned wagon)

Quote, originally posted by Banned wagon »
Ha ha that's just cruel to the people who don't know what the down low is!
I know, but at least i don't tease people that they don't..



Photos will explain all. It's not difficult.
Your car is pushing what's being done to foxes, it's time mine moved the bar a little again too.
 

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Re: The End of the High is Nigh! Say good to two inches. (the brit)

Quote, originally posted by the brit »

Photos will explain all. It's not difficult.
Your car is pushing what's being done to foxes, it's time mine moved the bar a little again too.

ahh a bar that what a ran over i was wondering what that was stuck under my oil pan..
 

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Discussion Starter · #4 ·
Re: (Mikey_vr)

Quote, originally posted by Mikey_vr »
more pics plzzzz

Of what? Struts or the car?
The struts - I haven't made any progress in the last 4 hours.
The car, here you go:









Modified by Longitudinal at 4:41 PM 7-8-2007
 

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Discussion Starter · #6 ·
Re: The End of the High is Nigh! Say good to two inches. (blkparati)

Quote, originally posted by blkparati »
Cut to fit Rabbit struts and you will be low



That's it exactly
 

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Re: The End of the High is Nigh! Say good to two inches. (the brit)

I was cruizing through some Brazilian sites once and found a pic of a strut that the tube was completley gone and the steering arm had been altered so that it was pointing in a downward angle.The wagon looked like it was sitting about an inch off the ground.If I find it again I'll post it.



Modified by blkparati at 5:08 AM 7-7-2007
 

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Discussion Starter · #11 ·
Re: (jackfrost1031)

Quote, originally posted by jackfrost1031 »
c'mon jaime you tease.

I will post photos when there's something worth posting

I've got a timing belt job to do first this morning, then it's onto the fox. I've got the E30 mounts installed, and there might be some powdercoating done tomorrow. I'm kinda excited about all this
(well, not the timing belt).
 

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Re: (the brit)

Quote, originally posted by the brit »

I will post photos when there's something worth posting

I've got a timing belt job to do first this morning, then it's onto the fox. I've got the E30 mounts installed, and there might be some powdercoating done tomorrow. I'm kinda excited about all this
(well, not the timing belt).

Yeah me too as I plan on replicating it as soon as you get it done and I happen to have money to do so.
 

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Discussion Starter · #13 ·
Re: (jackfrost1031)

Can someone change the title of this thread to "say goodbye to two inches"..

I've done welding the first strut, and am waiting for it to cool before i put the insert in, then go test fit. Not really sure at this point what it's going to do to the steering components yet, it's all theory right now

Photos to follow.. Be warned though, when i'm worried about welds being strong enough, they tend to get less pretty - i have a habit to doubling and retouching parts, for better or worse.
 

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someone finally doing the strut mod I've been begging someone to do for years, right on.
I remember when I built my C/Os looking at the housing and thinking "i really just want to cut that".
 

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Re: (HiJinx)

Quote, originally posted by HiJinx »
someone finally doing the strut mod I've been begging someone to do for years


With some firm measurements and known inserts.... I'll be sawing up my extra housings.
Jamie: Will you be turning the steering arm in for tire clearance?
 

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Discussion Starter · #16 ·
Re: (BillLeBob)

Quote, originally posted by BillLeBob »


With some firm measurements and known inserts.... I'll be sawing up my extra housings.
Jamie: Will you be turning the steering arm in for tire clearance?

I finished one side (and am not amazed with the drop yet), but while building it, i did notice that the stock arm is angled inwards from the factory. I never noticed this before.
I have never needed extra clearance from the steering arm, so changing the angle was not something that i considered. In fact, i took great care to try to keep it as close to stock as normal (although it can be adjusted via the tie-rod while on the car).
In the end, all this work for about 45mm is sort of a PITA. At least at the same time i'm going to Bilstein Sports and new mounts etc. I feel as though i'll still have wheel gap with my stretched tires..
 

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Discussion Starter · #17 ·
Re: (BillLeBob)

Quote, originally posted by BillLeBob »


With some firm measurements and known inserts.... I'll be sawing up my extra housings.

Oh, and you heard it officially here first:
Rabbit fitment Bilstein Sports inserts are ~46mm shorter than fox inserts.
Cut off 46mm from your housings, and reweld. You can be +/- ~2mm due to the the size of the threaded cap that holds the insert inside the housing.
I got my Bilstein Sport inserts for under $100 each, PM me if you want some.
 

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Re: (the brit)

Quote, originally posted by the brit »


Rabbit fitment Bilstein Sports inserts are ~46mm shorter than fox inserts.

Now thats what I'm talking about.
 

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Discussion Starter · #19 ·
Re: (the brit)

Quote, originally posted by the brit »
Can someone change the title of this thread to "say goodbye to two inches"..

change it again to: say goodbye to 46mm, not 6xmm.
 

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Discussion Starter · #20 ·
Re: (ryubiggie)

Quote, originally posted by ryubiggie »
i can't wait to see pics.

I need a new set of upper spring perches for 2.5" springs before then... Anyone? Anyone? Bueller?
 
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