Ultra low VW fox coil over install and strut housing mod

OK this i my current project should finally be able to bring down my fox to a proper ride height. First you get out all of your fun measuring tools and start taking notes.

ok all measured up

Next get a set of strut inserts of your choice. I chose the bilstein MK1 sports.


Measure the difference between the old stock struts and the new.


Time to start cutting! first the spring perch.




All cleaned up.


So planing on making new shorter steering arms for quicker steering. Also I can rotate the steering arms in to allow for more clearance for wheels and tires.

I will clock the steering arm back to be parallel with the wheel angle. The steering arms will be shortened 1" as well. This is a vary crude white board drawing of whats going on.

OK got all my pieces finally so now its time to start the fun stuff.



I am so lucky to have a really nice uncle who let me go to his work and helped me with the rest of the fab work!
First i cut out new steering arms out of 1/2" plate steel.

Then drilled out a 50mm hole.

punched out a 1" hole

Next step was a real pain. the tie rod has a tapered hole to bolt in to on the steering arm.

So i cut off the steering arm! scary..


To get the metal bung out of the stamped steel arm took a little effort.





Now with all the pieces to the new steering arm ready to get welded up.




Ok the big Chop, no going back now! cutting out about 2" out of the strut housing!





Well that wasn't so bad. A little cleaning and sanding ready to weld back together.

Clamped the tubes in to some angle to aline the two Pisces. Time to fire up the welder. (thanks again T)


This step I had the pro step in and help.



Wow He made that look easy!

Welded the steering arms together next.



Getting the steering arms all lined up took a wile but once in the right place it just welded in place




All welded up !! (Nice welds T you rock!)



Now a test fit of the coil over sleeves



Sweet! fits like a glove! Now some detail work.
Sanded and smooth

Metal etch primer


then some paint



It was so hard to have to wait for paint to dry! Finally dry the finished product!


All assembled





Just need to buy some springs now. Oh and build the rear coil overs too but they are much easier

Wow I am really happy with the results! Cant wait to get them back on the car!
Thanks again T for all you help