Coil over rust prevention?

Razzle,

If you are really worried, prime with zinc primer first and weld through it, or tape the thread onto the tube at the top end then use a wire wheel to remove the paint at the lower end so that only paint below the threaded part is removed (my choice), then repaint once welded.

Only weld the bottom otehrwise you might not get the collar over th weld.

You only need 3 or 4 15mm long welds on the threaded bit. Even if a weld were to break, the force is down and it is very unlikely the threaded tube would slide over the welds.

Watch your amps on the welder - must be high enough to penetrate the tube nicely without leaving a big dag inside that the shockie cant slide past.

Obviously take the shocks out when welding.

Ash

Thats how I've done it, and have had the struts on 2 different cars over about 8 years and they are still going strong.

Ash i thought i would just say i did exactly what you said. Taped it, filed through the paint and did weld sections and repainted.
Thanks.