How’s it going everybody. I just wanted to share a how-to with you guys on how I build my gas shocks. It took me a while to get to this point in making them the way I wanted them to be, sturdy and useable. I hope you can make them and put them to good use. I will try to describe the procedure in each photo to help you a long the way. Thanks tony

I started out with aluminum 1/32″ Rod, 1/16″ and 3/32″ tubing.

I cut the length of how many shocks I need to the lengths I needed of 3/32″ tubing. Cut a extra inch invade of screw up and for the next step.

Chuck the 3/32″ tubing in a drill. The reason for this is to sand the sides down to about .085″ so they look real in size. I started out using 400 grit paper then when I get to around .085″ I start using lighter grit paper. Work my way to about 2000 grit so I can buff when finished.

After I buffed the 3/32″ tubing down to size. I then chamfer one end of the the tubing using a board file. This will be the end that goes towards the top of the shock and the I cut it to length. I then cut a piece of 1/16″ tubing that will insert into the 3/32″ tubing along with a cut price of 1/32″ Rod

As you can see in this picture I inserted the 1/16 tubing leaving about an 1/8″ sticking out of the chamfered end of the tubing in the next picture i I will explain why.

I then added the small cut 1/32″ Rod in the same chamfered end. Just add enough of the 1/32″ Rod so not to interfere with the Rod of the bottom part of the shock. The slightly crimp into place. Don’t go crazy with the crimping, you want it to look like the correct thickness.

As you can see the top halves are done and ready for the next step which comes later.

Now we start on the bottom shaft of the shock. After you chamfer the ends cut to size like a normal shock. Then repeat the procedure sat. The top part of the shock. Only this time cut the over the length you need the shock to be. You can size later when ready to assemble.

Repeat shot of the crimping of the lower Rod part of the shock. Remember it crimps at the slightest touch. So be careful not to apply a lot of pressure.

No you want to sand your ends down and round them off like a real shock. I use a rifle flat file and a board file to finish it up. Then cent of the mount of the shock ends drill a .020″ hole. I use R&B motion hardware but you can drill to any size depending on how you are mounting them. Take in mind these will move and are stable so if ya want movingly free suspension mount with good hardware.

Now just hand buff or buff out with a rotary tool and buffer. Cut the rods to length of what you need. there you have a Kool looking chrome shock the works with a moving suspension.

The iPhone Picts don’t do them justice but you get the idea. Here’s a side shot to kinda give you a guide on how hard to crimp.