DIY: Installing CG/CH Bonnet Struts

ABS

Active Member
Premium Member
Hi all! I reckon its time for another CG-CH DIY.

So I thought I might put up a set of small steps together for anyone wanting install bonnet struts, dampers (whatever you call them) on their CG/CH.
I would imagine the CG process to be similar to the CH, as long as you've got similar mounting points.

I know rigby did a similar DIY for based on the CC but there are some small differences/issues in this as you will see. Mine will be specifically for CG/CH and with lots of pics and a video... YES a VIDEO!!!

Moving on...

Materials:

  • - pair of bonnet struts (with mounting kit) from these guys: http://cgi.ebay.com.au/ws/eBayISAPI.dll ... 1279769646
    - socket set with 10mm and 12mm sockets
    - small adjustable spanner (to tighten fender ball screws coz tight location)

    - a helping hand (though is still achievable by 1 person)
    - small mallet (optional - in case strut decides not to attach to the ball screw or bracket nipple)
    - grease (optional)

Steps:

  • 1. Check that you have all of the following mounting kit items
    1.JPG


    2. Lift up the bonnet as you normally would, using the existing metal arm to support it - pretty basic. Test fit the brackets over the existing upper bonnet bolt on either side. Do this for both sides.

    Note: 'L' is intended for the passenger side and 'R' for the drivers side.
    2.JPG


    4a.JPG


    Also note: With drivers side, the washer hose seems to get in the way of the bracket so you simply lift this up slightly and it will sit above the bracket.
    2a.jpg


    3. Start with the bonnet first since this the entire process depends on how well these fit.
    First remove the upper bolt on the passenger side using the 12 mm socket and setup the bolt using the washers and bracket, as follows.
    4a.JPG


    3.JPG


    4. Bolt the bracket on to the bonnet and tighten as much as possible - coz the last thing you need is this to break loose.
    4.JPG


    5. Follow steps 3 and 4 for the drivers side too.

    6. Now on to the fender bolts. Remove these using a 10 mm socket and replace this bolt with the ball screw and small washer, on both sides. Tighten using a spanner unless you have a deep socket to fit over the ball screws.
    6.JPG


    7. Easiest parts are now complete!!
    Next is where you will be actually linking the ball screw nipple with the bracket nipple. Remove these pins from both sides of the strut - there are 4 in total and try not to misplace them!!
    7.JPG


    It already has some, but if you wish, apply more grease on the insides of the swivel assembly, where it will be linked to the bracket and ball screw nipple (for longevity).

    8. Since I was doing this by myself, I found it easier to mount the fender side first. To do this, you'll need to simply place the black swivel (smaller end) on to the fender ball nipple and press down to lock in. Then secure with the slip-proof pin.
    Note: Once you lock in the fender side, you can swivel the strut bar in any position you want, in order to get the pin through the holes and clamp down.
    Also Note: If the slip-proof pin doesn't go freely through the holes, then it means the swivel part isn't locked in properly!!

    Do the same for both sides.
    6a.JPG


    9. This step will be easier for you if you have someone to hold up the bonnet while you play around with the ever-so-fussy slip-proof pins.
    What I did here was, while the bonnet was still up from the existing metal bar, I slightly lifted up bonnet with one hand and got the black swivel (larger end) on to the bracket nipple on the bonnet. This also needs to be locked in and in some cases, it may be stubborn - slightly tap with mallet.
    Then secure with the slip-proof pin.

    Do this for both sides.

    10. Now make sure everything is tightened and secure. Then put down the existing metal bar but I advise you not to remove this, just in case.
    Test the bonnet struts in action and ensure that it clears when you push the bonnet down to lock.

    10.png


    It should automatically drop down, from 1/2 to 3/4 way down, AND lift up itself from 1/4 to 1/2 way up.

The finished product (video):
[youtube]http://www.youtube.com/watch?v=X-hAhQAzNKg[/youtube]


More info can be found in this thread: viewtopic.php?f=9&t=6812

Any questions, post below otherwise enjoy guys!! :)

P.S.Next DIY may involve retrofitting CJ or similar boot struts ;)
 
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