Hello. I want to do a quick intro and make a couple of comments on cutting bump stops. I live in Michigan and got my first BMW in October, a Alpine White 535iM in great shape. I have been lurking here and posting occasionally as I work my way through restoring stuff on my car. I have spent the past 30 years as an automotive engineer and every time I take something apart on the car I am just amazed. So much attention to detail and over-engineering. These cars are a far cry form the domestic cars I've been engineering throughout my career. BMWs are made to come apart and go back together without busted plastic bits laying all over the floor when you are done. What a treat to work in these cars!

I am currently installing the Sachs suspension kit and want to hear opinions on cutting the front bump stops down. It seems that the only correct way to cut them down would be to take some out of the middle and glue the two ends back together. The bottom of the stop (cone-shaped) is designed to carry the dust boot and can not be cut off or the boot will just slide down the strut housing without protecting the strut shaft. The top end of the stop has a smaller inside diameter which keeps the stop / boot assembly in the correct position at the top of the shaft for the stop to work and to hold the boot up covering the shaft. I decided not to cut them down and we'll see if they bottom out too often. Has anybody cut these down and how did you actually do it?

Anyway, great forum and a great bunch of very helpful BMW enthusiasts. You have all helped me out with lots of little project on the car...