How to Compress a Gas Strut for Fitting: Step-by-Step Guide

Why Compress a Gas Strut for Fitting?

Gas struts, also known as gas springs, are commonly used to provide support and controlled motion in various applications, from car boots and bonnets to furniture and industrial equipment. These struts rely on compressed gas to exert force, making them initially extended. Compressing a gas strut is often necessary for installation, especially when space is limited or the strut needs to be aligned with its mounting points. This article provides a comprehensive guide on how to safely and effectively compress a gas strut for fitting, ensuring a smooth and successful installation process. If you’re unsure about the force requirements of your struts, use our Gas Spring Force Calculator to get an accurate estimate.

What Happens if You Don’t Compress Properly?

Attempting to force a gas strut into place without proper compression can lead to several problems:

• Damage to the Strut: Applying excessive force can damage the internal components of the strut, such as the piston or seals, resulting in premature failure.
• Injury: Gas struts store significant energy. Improper handling can lead to sudden release of force, causing potential injury to yourself or others.
• Misalignment: Without controlled compression, aligning the strut with its mounting points becomes difficult, potentially leading to improper installation and reduced functionality.

Tools and Materials Needed

Before you begin, gather the following tools and materials to ensure a safe and efficient compression process:

• New Gas Strut: Ensure you have the correct replacement strut. Refer to your vehicle’s manual or the strut’s part number.
• Soft Cloth or Padding: To protect the strut’s surface from scratches during compression.
• Safety Glasses: To protect your eyes from any potential debris or accidental release of pressure.
• Gloves: To provide a better grip and protect your hands.
• Suitable Leverage Tool: A sturdy pry bar or similar tool that can safely compress the strut – avoid sharp edges that could damage the strut body.
• Assistant (Recommended): Having someone to help hold the strut in place can make the process easier and safer.

Step-by-Step Guide to Compressing a Gas Strut

Step 1: Preparation and Safety Measures

Before starting, ensure you are working in a well-lit and clean environment. Clear any obstructions and ensure you have ample space to maneuver. Put on your safety glasses and gloves to protect yourself. Place the soft cloth or padding on the surface where you’ll be working to prevent scratches on the strut. Knowing the correct gas spring Newton force assists in safely handling the strut.

Step 2: Position the Gas Strut

Hold the gas strut with the rod end facing downwards. The body of the strut should be resting on the padded surface. If you have an assistant, ask them to hold the strut securely in this position.

Step 3: Apply Controlled Pressure

Using a sturdy lever or pry bar, gently apply pressure to the end of the rod. The goal is to compress the rod into the cylinder. Ensure the force is applied evenly and smoothly. Avoid jerky or sudden movements, as these can damage the strut or cause it to slip. Remember, if you’re working on a vehicle, ensure the automotive struts match the required specifications.

Step 4: Compress the Strut

Continue applying pressure, gradually compressing the rod into the cylinder. As the strut compresses, it will require more force to maintain the compression. This is where having an assistant can be beneficial, as they can help hold the compressed strut in place while you prepare for installation. Ensure you compress the strut enough to align the end fittings with their mounting points.

Step 5: Secure the Compressed Strut (If Necessary)

If you need to pause or take a break during the compression process, secure the compressed strut to prevent it from extending suddenly. Use a clamp or strap to hold the strut in its compressed state. Ensure the clamp or strap is securely fastened and will not slip. However, avoid leaving this compressed for extended periods, it’s best to fit the strut right away.

Step 6: Install the Compressed Strut

With the gas strut fully compressed, carefully align the end fittings with their respective mounting points. Secure the strut in place using the appropriate fasteners, such as bolts, clips, or screws. Ensure the fasteners are tightened to the correct torque specification to prevent loosening or damage. If you need to replace an existing strut, see our guide on how to measure a gas strut.

Step 7: Release the Compression

Once the strut is securely installed, carefully release any clamps or straps that were used to hold it in place. The strut should now be properly installed and functioning as intended. Test the operation of the strut by opening and closing the lid, door, or other component it supports. Ensure the movement is smooth and controlled.

Alternative Methods for Compressing Gas Struts

While the step-by-step method described above is effective, here are some alternative methods you can use depending on the available tools and the specific application:

Using a Vice or Clamp

A vice or clamp can be used to compress smaller gas struts. Place the strut between the jaws of the vice and slowly tighten the vice to compress the strut. Use padding to protect the strut’s surface. Ensure the strut is aligned properly to prevent bending or damage. This method is particularly useful for compressing gas struts used in furniture or smaller applications.

Utilizing a Spring Compressor Tool

Spring compressor tools, commonly used in automotive suspension work, can also be adapted for compressing gas struts. These tools provide a mechanical advantage, making it easier to compress stiffer struts. Attach the spring compressor to the strut and gradually tighten it to compress the strut. Ensure the tool is securely attached and will not slip during compression.

Safety Precautions and Tips

Working with gas struts involves potential hazards due to the compressed gas they contain. Here are some essential safety precautions and tips to keep in mind:

• Always Wear Safety Glasses and Gloves: Protect your eyes and hands from potential debris or accidental release of pressure.
• Never Puncture or Disassemble a Gas Strut: Doing so can cause a sudden and dangerous release of compressed gas.
• Avoid Applying Excessive Force: Applying too much force can damage the strut or cause it to slip, potentially leading to injury.
• Work in a Well-Lit and Clean Environment: Ensure you have ample space to maneuver and that there are no obstructions in your work area.
• If in Doubt, Seek Professional Assistance: If you are unsure about any aspect of the compression process, consult a qualified mechanic or technician.
• Measure twice, compress once: Ensure that your replacement gas strut size is correct before trying to fit it.

Troubleshooting Common Issues

Even with careful preparation, you may encounter some common issues during the gas strut compression process. Here are some troubleshooting tips to help you resolve them:

Strut is Too Difficult to Compress

If the strut is too difficult to compress, it may be due to high gas pressure or a damaged internal mechanism. Ensure you are applying even and steady pressure. If the strut still won’t compress, consider seeking professional assistance.

Strut Slips During Compression

If the strut slips during compression, it may be due to an uneven surface or insufficient grip. Ensure the strut is resting on a padded, non-slip surface. Use gloves to improve your grip. If the strut continues to slip, try using a different leverage tool or clamp to secure it in place.

End Fittings Don’t Align Properly

If the end fittings don’t align properly after compression, it may be due to incorrect compression or misalignment of the mounting points. Ensure you have compressed the strut enough to allow the fittings to align. Check the alignment of the mounting points and adjust as necessary. If the fittings still don’t align, double-check that you have the correct replacement strut.

Where to Buy Replacement Gas Struts

Replacement gas struts are available from various sources, including:

• Automotive Parts Stores: Local auto parts stores typically stock a wide range of gas struts for different vehicle makes and models.
• Online Retailers: Online retailers like offer a vast selection of gas struts, often at competitive prices. Make sure they have a fitment guide to get the right one.
• Specialty Gas Strut Suppliers: Specialty suppliers, such as Aritech Gas Springs, offer a comprehensive range of gas struts for various applications, including custom sizes and specifications.

Remember to verify the dimensions and force needed to ensure the replacement strut matches your needs. You can find the right specifications by referencing the original strut’s part number or the equipment’s manual.

For bespoke or bulk orders, contact our industrial team. Also, check our article Gas Strut End Fittings Guide to ensure you have the correct parts.