DIY: BlauSport Struts
Monday got in the passenger side front one - SO MUCH EASIER; it makes such a huge difference when you know exactly HOW TO DO it 
Yesterday I rented the compressors from AutoZone and I replaced both rear struts in about 5 hours, give or take. It took me though about 45 minutes to undo the top nut on the first one, until I found a vice-grip with the CURVED jaw. I personally only had a straight jaw one, and the damn shaft was spinning in it no matter what.
Boy, what the difference in ride!!!! Actually all 4 struts were shot...
I subscribe to everything you said about these struts, Jim. Even the cornering improved, and same way as you said...with no body roll.
However, I still have thuds especially when going over dips, so I suspect the bushings on the control arms are shot as well. That can wait though...unless I find some "holiday" prices on good control arms.
P.S Blaufergnugen forgot to send new lower spring stops... but after a year probably would have been worthless to even contact them about it... I had to use the old ones.

Yesterday I rented the compressors from AutoZone and I replaced both rear struts in about 5 hours, give or take. It took me though about 45 minutes to undo the top nut on the first one, until I found a vice-grip with the CURVED jaw. I personally only had a straight jaw one, and the damn shaft was spinning in it no matter what.
Boy, what the difference in ride!!!! Actually all 4 struts were shot...
I subscribe to everything you said about these struts, Jim. Even the cornering improved, and same way as you said...with no body roll.
However, I still have thuds especially when going over dips, so I suspect the bushings on the control arms are shot as well. That can wait though...unless I find some "holiday" prices on good control arms.
P.S Blaufergnugen forgot to send new lower spring stops... but after a year probably would have been worthless to even contact them about it... I had to use the old ones.
Last edited by chefro; Nov 17, 2010 at 10:31 PM.
I'm posting several photos that are meant to compliment Jim's wonderful and EXTREMELY USEFUL write-up (thanks again, JIM - your insight was priceless), as the job itself most certainly applies to any strut brands (inserts) others may choose to go with.
Again, I'm only trying to highlight a few things about the job I found to be of interest, or that lacked visual aid in Jim's very thorough description.
-
The Pipe Wrench (18 inch) use on the Threaded Cap:

-
Best spot to jackup the suspension to expose the shaft when removing it (and not only then):

-
One modality to pull the cartridge up (with the upper nut screwed back in), via pipe wrench:

-
If you can't budge it with the 18inch wrench, then grab a 36" one:

-
Installing the Dust Boot from above, same as in Jim's description:

-
The plastic cover I was talking about, the dust boot's lower edge fastens onto:

-
And the boot fastened onto it, before inserting the cartridge:

-
Zip-tied it before sliding it over the Threaded Cap, which I already tightened:

-
New upper mount is spot on the markings:

-
One modality to remove the upper nut on the rear strut - the old cartridge is in the vice, and I use a breaker bar for better leverage, while the CURVED JAW vice-grips are holding the shaft:

-
If are not rusted, the old lower coil stops can be reused (as said, Blau didn't send me new ones... so much for trusting anymore a certain vendor, nowadays):

-
I personally didn't have to lower the suspension to fit the assembly with the new insert in - lower bolt is in already, as the suspension loweres itself when removing the lower bolt; As I recall Jim's is a Quattro, so the rear suspension on mine is much simpler:

-
I also found it really helpful to fasten one upper nut (again, the lower bolt was already in place) before jacking up the suspension:

-
This last pic shows the assembly in with all three upper nuts screwed in, just before jacking up the suspension to torque everything to specs:
Again, I'm only trying to highlight a few things about the job I found to be of interest, or that lacked visual aid in Jim's very thorough description.
-
The Pipe Wrench (18 inch) use on the Threaded Cap:

-
Best spot to jackup the suspension to expose the shaft when removing it (and not only then):

-
One modality to pull the cartridge up (with the upper nut screwed back in), via pipe wrench:

-
If you can't budge it with the 18inch wrench, then grab a 36" one:

-
Installing the Dust Boot from above, same as in Jim's description:

-
The plastic cover I was talking about, the dust boot's lower edge fastens onto:

-
And the boot fastened onto it, before inserting the cartridge:

-
Zip-tied it before sliding it over the Threaded Cap, which I already tightened:

-
New upper mount is spot on the markings:

-
One modality to remove the upper nut on the rear strut - the old cartridge is in the vice, and I use a breaker bar for better leverage, while the CURVED JAW vice-grips are holding the shaft:

-
If are not rusted, the old lower coil stops can be reused (as said, Blau didn't send me new ones... so much for trusting anymore a certain vendor, nowadays):

-
I personally didn't have to lower the suspension to fit the assembly with the new insert in - lower bolt is in already, as the suspension loweres itself when removing the lower bolt; As I recall Jim's is a Quattro, so the rear suspension on mine is much simpler:

-
I also found it really helpful to fasten one upper nut (again, the lower bolt was already in place) before jacking up the suspension:

-
This last pic shows the assembly in with all three upper nuts screwed in, just before jacking up the suspension to torque everything to specs:
Oh ya.. yours is a non-quattro.. makes the rears MUCH easier 
I do believe, however, that Blau meant for you to reuse your lower coil stops/seats as mine where one piece with the strut. I have seen this elsewhere.
Ride good, no?
Good Job!

I do believe, however, that Blau meant for you to reuse your lower coil stops/seats as mine where one piece with the strut. I have seen this elsewhere.
Ride good, no?

Good Job!
Well, as said, it is easy to do it when you know how and what to do...thanks to you! 
Got myself now new brakes all around and struts. LOL
I need to replace sometime the control arms (or whatever else is the culprit for the still existing thuds), and to change the ...Rear Main Seal, but I need to bite a huge wad of confidence (or drink a lot
) before starting to pull out the engine...hehehehe

Got myself now new brakes all around and struts. LOL
I need to replace sometime the control arms (or whatever else is the culprit for the still existing thuds), and to change the ...Rear Main Seal, but I need to bite a huge wad of confidence (or drink a lot
) before starting to pull out the engine...hehehehe
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