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Old 03-30-2017, 11:24 AM   #1
Nick M3
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Join Date: Oct 2003
Location: Bethesda, MD
Posts: 12,438
Shock Repair

So, there was a slight incident with overtightening a shock bolt on Mike's E90 (wasn't me!). Unfortunately, this was a Bilstein PSS10 damper, and Bilstein's excellent customer service response was "Fuck you, buy another set. We won't even sell you the individual shock."

While we were noodling repairing it, I pinged a friend about a couple of different approaches to solving the problem. Basically, this came down to either carefully and very slowly welding a bolt to the end, or drilling/tapping and shoving a stud in. His opinion was that the weld on option would probably work, but that it was a last resort. And also that he could knock out a "good enough" drill guide and get it done in about 15 minutes, so I should just bring it over after work.

Making the drill guide:





Chopping off the end of the shock:





Drill guide rigged up (if this was going to get more than a couple uses, a drill bushing would be good, but not needed here):


Drilled:


Studded:


Eric:
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