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All right guys, I'm doing the Koni insert replacement thing. Read Jmauld and Berserko's helpful instructions. Clear enough. Got my Koni's and saw that their instructions were all pictorial -- no text. OK, no problem; seemed straight forward and consistent with prior instructions. All went well until I went to put the nice, enameled, yellow insert into the old casing (from an AWD Talon, which, I've been told is the same size as our C/M's). It seems that the outside diameter of the insert is virtually identical with the inside diameter of the casing. That equals no fitment without help. (1) Am I missing something? Nobody talked about this problem. (2) Should I try an oil or silicone lube and force (hammer?) it in? Doesn't seem right; could never get it out. (3) Find a lathe and take a turn on the nice, enameled, yellow insert? Seems the most practical and efficient way unless somebody else knows something. I'm going to Email Koni on Monday. Maybe they sent the wrong size. Help or sympathy, please. Bill Spruill, oldest Colt

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Age is a number; attitude counts.

I didn't have any trouble with mine sliding in to place. Did you remove the burrs that resulted from opening the oem struts? You're not using aftermarket struts for the conversion are you, because those could be a little different. If you are, let me know. I think I have another set of oem's laying around somewhere.

Hi Jason, These were oem struts. I did use a pipe cutter to take off the upper collar. I then filed the inside and top, mainly to remove any rough edge. You raise hope. The pipe cutter did raise a miniscule ridge. It was filed smooth but perhaps the ridge is a RCH high. I'll use a Dremel tomorrow to insure a slight flare out. Well, here's hoping. Bill

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Age is a number; attitude counts.

Well, I couldn't wait. I don't have a Dremel myself, but I remembered that I did have a "chuckable" grind stone and drill. So, I put it towork and really got that leading edge smoothe and flush. I put a little light oil on the insert and VOILLA! success. Everything went in like a prelubed xxx. Thaqnks again, Bill
Oh, I cut off the spring perch with a cutting wheel and ground the edge smooth. That was a bit of work.

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Age is a number; attitude counts.

Cool deal! Did you leave enough of the spring perch for the coilovers to sit on?