Rear shock install: how do I get the metal cap on Koni Yellows?
 

Doing an original shock replacement with Koni Yellows.

The stock rear shocks have a metal cap that fits down over the rod and seats on the shock body. It's a press fit.

I assume I need to transfer this to my new Koni Yellows, but the shock body is a little larger, so I'm not sure how to do it without damaging the shock or machining the cap.

Tips? Do you use a different part? Thanks!

yep you gotta drill it a little bigger

The cap fits over the rod no problem- the issue is the sides of the cap are too small for the body of the Koni. I suppose I will have to grind out the insides of it.

Surprised no one else has run into this as it's problematic even with an angle grinder. Hand filing that will take hours.

What is the part number on your new Konis?

Here's a pic of the cap:

http://thevenom.net/rx8/metalcapkoni.jpg

The red arrow points to the cap. My problem is the inner size of that metal cap is too small to fit around the yellow koni shock body. (It's a bit wider than the stock shock)

I resorted to grasping the cap with vise grips and beating with a hammer to bend the indents out, but I can't get enough to pound the cap on the koni shock body.

What am I missing? Thanks!

Part number looks like "8240 1227 SPORT" and underneath it says "24-2010" then "Adjustable"

Are both sides like this? Maybe Koni put the wrong cap on the strut? Or is your metal tube bent?

I have an '06 and my rear pieces are plastic. They're part of the stock shock. you don't need them on the Koni's.

I'd have decided that (leave them out) except the install instructions depict this part going on the new shock. It's what the bump stop contacts, and the stock suspension rx8 hits the bump stops constantly in even hard street driving.

Anyway, I persuaded it with a dremel and BFH. Thanks all.

Can you take a picture of what isn't fitting?
I didn't modify anything with my rear koni yellows.

Reply #5 has a pic. After conferring with other RX8 owners here with the same shocks, I removed the cap.

that part is not required on the Koni and it serves no purpose on it as they are intended for the bumpstop to hit the top without issue

Thanks! Car is 100% better with new shocks!

What shocks did you change to?

Did you miss the entirety of this thread??? He went from stock shocks to koni yellows

the factory shocks are not very good on the RX8 and the yellow Konis are the best choice for performance