Today we finally found the issue with the front struts! After countless strip down and reassembly sessions of the front struts, we found the mistake - which I made during assembly! When you go back to the beginnings of this blog, you might find this picture - the root of all evil!
The trick was used in the olden days, when oil pressured shocks were used. The Bilstein inserts are gas filled cartridges. There is a valve in the bottom of the cartridge which "breathes", depending on the movements of the shock absorber. Now, what happened and how did I found out?
When I took the strut apart today, I told my buddy to be careful, cause the strut is oil filled. When we poured the oil, it was almost nothing left of the initial 100 ml I inserted, maybe 10 ml only?
Then I tried to compress the cartridge all the way to full droop. I was irritated by the fact that it only worked about half way, then was totally blocked...
Here is the reason why, the valve basically sucked in all the oil, which then acted like a hard stop. So, the strut actually bottomed out on every pot hole and gave a harsh impact to the body!
Then we inserted the cartridge upside down in a bench press and tried to gently push the oil out:
Mittelmotor was required to buy another pair of inserts, this time B6 Sport - a hair stiffer than the standard B6.
Now, finally everything works well. I hope it stays this way. Happy days!