Hi 1200rallycar,
My front suspension uses 40mm Bilstein inserts into custom tubes. I use adjustable strut tops but they dont mount the top of the insert/damper like stock because the 40mm strut tubes are actually 50mm longer than normal. As you probably know the oil in dampers heats up very quickly and can take hours to cool back down so by running longer inserts means that the damper has more oil to act as a heat soak, in short better suspension in stages that are very long.
This means that once my bonnet is open and you look at the strut tops you see a thing that looks like a stainless steel tophat that extends up past the strut tower of the body by 50mm. All this means that I can run longer front dampers and still close the bonnet with about 10mm clearance.
I used to run rubber inserts in my extended strut tops but found when landing after big jumps that the rubber would flex and drive the damper ends up through the bonnet, not a good look
I use LJ Tonana radius rods which are much stronger than stock and have the strut tops set up so I have good cambers and around 5.5 degrees caster. The idea is to have everything super strong and fully adjustable.
I have just finished redisigning and building all this.
The stainless tophats have spherical bearings fitted and the lower control arms are all rose jointed.
I will get off my ass and organise some photo's after the next round for the ARC because I'm chief engineer for one of the teams.
Oh yeh, i almost forgot, I rally in the Canberra region.