Shortening struts

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If you lower your car more than 2 inches, the strut will start bottoming out. To mitigate this, shorten the strut. It's easy and can be done with or without welding.

Overview

Strut before and after shortening

Also, the stock spring seat has been replaced with an adjustable version

1. Cut tube in section. Don't cut towards the top as you need to preserve the internal tube threads for the strut gland nut
2. using your chosen short insert, shorten the tube to suit
3. leaving old inserts in the strut (covered in a smear of oil) stitch weld the tube back and grind back to the diameter. don't let it get too hot or you'll have an oil fire.

Additionally, you may choose to re-position the lower spring seat (or coilover adjustable sleeve) in a way that the leaves enough clearance for tyres.

1. Remove the strut/spring/brake assembly, then remove the spring and the strut shaft/insert.
2. Grind the lower spring perch free from the strut tube.
3. Cut the strut to the length you want. For a three-inch lowering job, cut the strut three inches. Have a machinist cut new internal threads for the large gland nut
4. place the spring perch where you want it and fasten securely. You can have it re-welded or use a commercial-grade shaft collar.

Choosing A Short Shock Insert

Since the stock strut inserts require the whole length of the strut tube, shortening the tube can only be done with using a shorter insert.

Stock Shock Absorber Cartridges for Datsun 1200 struts

Select a shorter insert such as the Pulsar unit or Golf unit. It can be very short (a spacer can be used in the tube), but should have a reasonable extended length. Also keep the stiffness in mind - stiff shocks may "feel" fast but actually results in slower race times. A great shock will let the suspension dig in for maximum tyre grip. The shock should damp oscillations from bump and rebound.

1981 Pulsar inserts are the same external size as Datsun 1200 but shorter by 82 mm (3-1/4 in) so if you are after lowering without banging on the spring mounts this is a easy way to go only 10mm (3/8) shorter in the stroke.

1981 Pulsar vs stock 1200

1981-1983 Datsun Pulsar (Datsun 310) 
Monroe GT Reflex part number 25-3436
* replaces WGC-3436 touring gas cartridge
* Total length:  525  mm
* Body length:   335  mm
* Body Diameter: 36.9 mm
* remove 75 mm (or less) from the tube, to allow for the locking ring nut to fit

Stock 1200 inserts
* Body Length:      418 mm
* Length Extended:  631 mm
* Length Collapsed: 462 mm
* Stroke: 169mm (6.7 in)

For more alternatives, see Strut Insert Part Numbers

Remove Spring Perch

Use a handheld grinder or a bench grinder. Be careful not to cut through the stut tube.

Cutting Strut Tube

Can a cheap tube cutter do the job? A pipe cutter might work but they're actually quite thick walled tubing so it might take a bit!

A good old drop saw (chop saw) does the trick on the tubes. It will hold the tube perfectly square and just cut it through (after removing the strut piston/insert of course).

Cut down, spring perch welds ground off

Ready to prime (use weld through primer to seal under where the spring seat will go)

Primed, now ready for fastening the spring seat

Fasten Lower Spring Seat

You can place the spring perch where you want it and fasten securely. You can have it re-welded or use a commercial-grade shaft collar.

See main article: Fastening Spring Seats