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It's funny this thread is back because I'm installing coilovers w/koni inserts right now. I used a hack saw to cut the perches off above the weld, intending to leave a flat surface for the coilover sleeve to rest on. Since I have the stock struts, there are only 3 welds.
Assembling the sleeve to them, for the most part I would have only 1 or 2 welds contacting the sleeve, regardless of how much I filed them down. I think if you're cutting the perches (unless you have illuminas with continous bead) it would be a good idea to remove the weld completely and have a steel collar fabbed up and welded for you...it gives you a nice even landing area for the sleeve.
Also, has anybody had problems with the clearance between the sleeve and the strut housing? The housing outer diameter is ~50mm, the sleeve inner diameter is ~52mm...not really a snug fit. Some people wrap the housing with duct tape as a spacer, then slide the sleeve on. Is this worth it?
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