Found a new bump stop option.

[Jason@SportsCar]

Originally Posted by FunctionSpec

Ok I think I found what caused the Bilsteins to prematurely break. After closer observation, I noticed the Bilsteins do not fully compress and that there's a 1.5 inch gap between the top of the strut body and bottom of the strut bearing. So a bumpstop that is 2.75in in length only has about 1.25in of up-travel before it bottoms out on the shock. If we estimate that the bumpstop compresses about 50% of it's length during a hard bump, that would be 1.38in of compression, which slightly goes past the amount of cushion these bumpstops provide. So really what that means, the bumpstops aren't protecting the shocks at a certain point and the shocks themselves are bottoming out during hard bumps.

I think the Bilsteins were designed to be used with the OEM bumpstops. There's a plastic spacer on the OEM bumpstop that limits up-travel by about 0.75 inch. Full length of the OEM is about 3.5in. The plastic spacer provides some insurance to protect the shock but knowing that the OEM bumpstops will crap out in a year or two has me worried. A crumbling bump stop doesn't provide much protection.

Quite the dilemma here. I need a bumpstop that's at max 3.5 inches long, any longer than that and the car is pretty much riding on the bumpstops. A bumpstop that isn't too "squishy" and is firm without compressing too much. The Febi bumpstops I have compresses quite easily the first 0.5 inch and then stiffens up. But I do have some time to figure out since these Bilsteins are on backorder for 5-7 weeks

If you like the new stops you have just make a spacer so they engage early enough to prevent the strut from bottoming. With a cheap delrin cutting board and a hole saw you should be able to make a nice spacer.