Shocking Journey: The Fascinating Construction of a Bilstein Damper

►Bilstein has been a leader in suspension technology and design since their first damper was fitted to a Mercedes seventy years ago. In that time, they've supported Le Mans winners, damped the fastest cars in the world, and provided an expansive aftermarket for any vehicle owner chasing more performance. Each of their products is hand-assembled in a methodical process that ensures each damper, whether an OE-spec B4 unit or an electronically adjustable B16, is perfectly suited for consistent, world-class performance.
FCP Euro has a wonderful relationship with Bilstein, and on our last trip to Germany, we were invited to tour the facility and see how their world-famous yellow struts are made.
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0:00 Facility Introduction
2:00 Turning Raw Materials Into Damper Tubes
8:00 Forming The Strut Bodies
12:30 Testing An Assembled B16 Damper
16:48 Taking A Dip In Protective Coating
17:43 Setting Up The Shim Stack
19:35 Painting The Bilstein Yellow & Final Assembly
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[@fcpeuro-media]

Head over to FCPEuro.com to Save on Bilstein Products NOW During our Steering and Suspension Sale $10 off $199 | $25 off $499 | $50 off $999 using the code SPRINGSAVE at Checkout!

[@timothywing8604]

"We didn't drill it, we mill it. Its a rhyme." That was the most German humor, ever! lol.

[@fcpeuro-media]

Warms your heart haha

[@bizzfo]

We didn’t cut it, we mullet

[@robpeters5204]

I live in Ontario Canada and I absolutely love my Bilstein B1 front struts, rear shocks and coils on my 81 Mercury Capri I built back in 83-84! It lowered my car approx 21/2” in the front and 2” in back. You can jump on the front fender and it will bounce just slightly while stopping very quick. Yet it rides as smooth as glass. It corners like a roller coaster. The faster I drive the smoother it seems to be. I’ve never had any issues with them leaking or anything. I would put Bilstein products on everything I drive!

[@fcpeuro-media]

Amazing being able to have products from the same company on a build from the early 80s, and something as modern as a brand new supercar.

[@michaelbegay9573]

The difference between a $30-40 discount parts shock to a $200-300 premium/race shock..😳💪😉

[@mikeedwards1768]

worth every penny

[@vector150]

Bilstein struts and shocks best ever.

[@fcpeuro-media]

Certainly top of our list - why we use them on so many of our project cars!

[@rkan2]

Would be interesting to see a tour of the Sachs factory, e.g. the old BOGE factory in Eitorf before they ship it to somewhere asia after next year!

[@pmpwiz]

I've had Bilstein 5100s in my Jeep for 10 years now. No problems. But the damn thing rides like a friggin tank!

[@fcpeuro-media]

On a jeep - riding like a tank is the goal right? 😅

[@pmpwiz]

@@fcpeuro-media Which is why I chose them. No regrets.

[@8vfury]

Amazing to see how hand built this suspension is! pretty cool

[@fcpeuro-media]

Glad you enjoyed seeing the process!

[@funtdrv]

Thank you for making this video! Was a fascinating look at the process. As a frequent visitor to Germany, I enjoyed the humor and friendliness of the crew at Bilstein immensely!

[@fcpeuro-media]

They were great hosts, we really enjoyed our time there - as we asked a whole lot of questions along the way haha

[@edwardlong189]

I love Bilstein shocks.

[@fcpeuro-media]

We love that you love Bilstein shocks. Thanks for watching!

[@EthanRoyMedia]

It's so interesting to see how they are made, thanks for making this video!

[@fcpeuro-media]

Our pleasure Ethan!

[@Aungie-vz1be]

I always enjoyed the performance of Bilstein's on my vehicles and now thanks to you and Bilstein, I'm able to see what efforts go in to making the perfect shock. I have B8 performance on my F30 diesel and they perform absolutely wonderful.

[@fcpeuro-media]

Glad to hear you've been a Bilstein fan - now a chance to see some of the secret sauce!

[@kdao1007]

I love Bilstein. Thanks for doing these factory tour. Really impressive and keep them coming

[@fcpeuro-media]

Glad you like it - we've got more on the way!

[@albertcars4001]

The best shock's, no doubt.

[@gj91471]

For the price, the best..... But the ultimate is Reiger

[@TechScottBrown]

Great video, thanks for sharing!

[@alherch]

The labeling process looks like the process for cigars, very interesting. Thank you for sharing this, amazing that there are so many steps done by humans. Amazing!

[@ghostwrench2292]

Love the video! B8’s on my Volvo and B14 on my Mini R53. I love how my cars handle on Bilstein dampers!

[@fcpeuro-media]

We're sure that R53 is on rails!

[@user-so8zq4wv8v]

B6’s on my bench right now for install… can’t wait. TY

[@phillxor]

I had B6 on my last car - so good. Watching this video got me searching parts sites immediately for B6 the current car.

[@fcpeuro-media]

What are you putting them on!?

[@fcpeuro-media]

@@phillxor you know where to look! Running a coupon code that can be used on them right now as well for another week!

[@phillxor]

@@fcpeuro-media unfortunately the $244 USD shipping to Australia puts a real sting on the purchase. Do you have cheaper shipping options?

[@phillxor]

@@fcpeuro-media Mk5 Golf R32.

[@ThunderbirdRocket]

Nice 👍🏼 !

[@stevej5342]

Very enjoyable. Nice indepth and featuring actual people! Nice to know the shocks I just installed may have been made by them.

[@fcpeuro-media]

Always a cool moment to connect an actual human with something we sometimes forget was every made by someone!

[@PatricioGarcia1973]

have been using Bilstein since trying them on my e21. One of the best mods money wise for handling

[@fcpeuro-media]

They are a great option at their price point - this trip gave us even more appreciation for what they do!

[@tailsneon556]

Interesting to see the people and place where the B6s that are on my W204 came from

[@chandne]

The real beauty of Bilstein is the valving! Well, when it comes to their shocks anyway.

[@fcpeuro-media]

We have a SUPER in depth video coming out soon diving deep into the Shim process Bilstein goes through for each of the their dampers. Excited to share it.

[@Billydevito]

All three of my vehicles have Bilstein Shocks. 1. Mercedes Vito 2. VW Transporter T5 4 motion 3. C4 ZR-1 Corvette with the FX3 adjustables. I prefer the quality. They cost more, but they’re worth it. 👍

[@fcpeuro-media]

Very very into that line-up Billy!

[@speakersteve9586]

The need to make some fronts for my 2000 Accord..

[@gordonarmstrong1077]

Hopefully they're busy assembling the damptronic B6 set I've been waiting on since before Christmas.

[@fcpeuro-media]

🤔If it was through us - we can always make a call....

[@r0ckworthy]

I had an older 1997 Ford Ranger pickup truck a few years ago. When I bought it, all 4 shocks were old, worn-out, and leaking. I went on Amazon and ordered 4 new Bilstein 4100 series shocks for about $300. I was able to very easily install all 4 shocks myself in my driveway, because there was only 2 bolts holding each shock in place. I went for a test drive as soon as I was done replacing the shocks, and I went off-road and started laughing like a little kid because the difference was night-and-day! What a difference having good shocks make!!!! I couldn't believe the difference. I will use Billsteins for every vehicle now, if I can.

[@fcpeuro-media]

Really nothing more important than what connects your wheels (and you) to the ground!

[@r0ckworthy]

@@fcpeuro-media Yeah shocks are probably the most important factor in ride quality and handling, both on-road and off-road. You can have an old worn out piece of crap truck, but with new, even value-level Bilsteins on there, everything's fine.

[@octymocty132]

I'm Motor sports Company I use to work we got these by the bucket load sriped down rebuild with different oils and gasses and slapped another 250 on top on each one as sold like hot cakes

[@SonicProvocateur]

How does Bilstein handle custom valved coilover units like RUF and the cup cars? Through the hand welding/assembly desk?

[@SC457A]

There is a slim chance my Bilsteins came through there. I doubt it though, the SVT Cobra production run might not have been in that shops tasks back in 2002. Neat watching the process

[@gabeesquivelLethalZR1]

If you are on the oem ones, get some new ones direct from Bistein as the oem ones were made to SVT spec and not that great. Vert and Hardtop were different, I remember hardtop in my 03 and 04 were stiffer than the vert ones. 20 years plus on oems i bet its time to upgrade anyways...

[@useryggfdcc]

Bilstein 6112 and Bilstein 5100 on my Taco working flawless roading.

[@Walker71820061]

Can out of warranty repairs be done? If so, how much? The right front strut threads on the shaft stripped on the first day of installation. BMW E36 W/B6 shocks/struts paired with H&R Sport/race springs & stage 2 Kmac adjustable camber plates up front.

[@crozwayne]

in the mid 70s till 83 I worked as a tool setter in the Girling factory back when we made dampers, no long gone

[@fcpeuro-media]

Wow very cool though - I'm sure some things have changed quite a bit since then?

[@2sc458]

I got Eibach Springs and Bilstein shocks on a car. That thing drove so flat in the turns. The Bilsteins were great.

[@fcpeuro-media]

Their collaboration for cup kits with Eibach are awesome!

[@RobertKohut]

Shocking... :-)

[@fcpeuro-media]

huehuehue

[@mk3whitewide]

I've always wondered how the innards move when I grip through corners on my b16s. I thought it was pure freaking magic this whole time.

[@fcpeuro-media]

🤣Even after seeing all this, we like to think theres still a bit of magic to it all. We get really into the dark arts of suspension tuning in the next video.

[@DrHumorous]

I have just purchased two front B6 shocks and the left one has a different (M8) top rod rectangle (to hold the rod while tightening the top nut) than the right one (M10). Is there an explanation for that?

[@fcpeuro-media]

Not one we are familiar with - but of course something we can look up.

[@DrHumorous]

@@fcpeuro-media Thank you for your kind attention

[@johnd.5601]

My Mustang came with Bilstien shocks and struts. This option made my Mustang worlds different from the other suspension packages. I replaced them with some coilovers. I ripped those coilovers out and brought a new set of shocks and struts from Bilstien. They are literally far superior to any other suspension options!

[@fcpeuro-media]

Full circle on that one! They know what theyre doing for sure - we dive deeper into the ride and handling RnD and Valving process in a future video!

[@justindaniel5959]

Is the Bilstein B12 comfortable setup for a daily car? BMW F30…

[@fcpeuro-media]

The B12 is an excellent option for anyone looking to drop ride height a bit while still staying dailyable. If you have damptronic like our F30 - even better!

[@xg5zm]

I saw too many tubes going inside other tubes, that is for a monotube shock absorber manufacturer. 😂😂😂

[@notmedicman]

If only they stood behind their products. One strut and one shock failed at 34 and 51 days after purchase. Retailer said Bilstein should cover and Bilstein said it should be covered by retailer return policy. Neither would cover the defect. Ended up replacing everything with a different brand. No problems for over a year with my American made suspension.

[@mustangdemon87]

Don't blame manufacturer for a scrappy retailer. Been using and installing bilstein for more then 20 years. Only ever had issues with warranty when it was customer damage or improper installation

[@InCountry6970]

A factory from 1873, making shock absorbers before cars were around, wow.

[@fcpeuro-media]

BIlstein was originally manufacturing window fittings in this plant back in 1873! Amazing how things can change within 1 company over that many years.

[@dmcnamara9859]

Cool video,but experience with Bilstein shocks ( whether gas filled hydraulic or normal hydraulic) end ride is too firm and brutal. What's the point of driving any car ( with OEM/ Aftermarket dampers) if the shocks/ struts just beat you and car structures up?

[@markus9333]

Bilstein very good but the best is Öhlins

[@nickguerra1905]

mk7 jettas need those b6 shocks baby seems like it taking forever to get them or if they even will make them

[@fcpeuro-media]

We did talk at length with the Bilstein team about lead times and supply chain, hoping we see improvement across the board there as time goes on!

[@knickebien1966]

2:38 Thomas Beer-Brewer? nur in Deutschland!

[@justinp2993]

Next time can you ask them why 1 of 4 of their shocks sounds different and presumably is performing differently to the point where I question replacing it immediately? I can do this on my personal vehicles (even on personal cars the ridiculousness of changing a shock 3 times is not lost on me (old one out bilstein in, bilstein out old one back in temporarily, then replacement bilstein one in)) but on customer cars I find it nearly impossible to recommend Bilstein as a brand. Maybe the higher end products are better but the B4 B6 lines I am typically around do not seem to have any where near the quality control Bilstein used to have in the 90's early 2000's.

[@spoolindsm127]

Damn I've been looking at B6's for an E90 M3 and feared this might be the case. Not sure what to go with now...

[@justinp2993]

Are you doing the work yourself or not, if you are then there is the riskier painful way I described above. I go through it on my personal cars because frankly the Bilstein recipe is just right when they are all working. I have to imagine that Koni makes a yellow for the M3, that would be my next choice but they will generally be a little stiffer than the Bilstein. When I've driven e90 M3's they always seemed a little stiff for daily work for me depending on the local roads so a little stiffer yet with the Koni might not be the best option. IDK it's a hard decision to make and one you get to live with for a long time.@@spoolindsm127

[@rybread97]

@@spoolindsm127I ran KW V1 coilovers on my e90 335 xDrive, really good setup considering the inherent poor handling and stiff ride of the e90 xDrives. If you don’t want to go coilover, have you looked into bilstein b8’s? I know BimmerWorld has them for the e90 m3 for around $800

[@fcpeuro-media]

We can for sure share your feedback with the team there. Appreciate the insights all around!

[@spoolindsm127]

@@rybread97 Thanks, I've looked into V1's but general consensus seems to be they're stiff and not as comfortable as Ohlins. I know, different price range and all. But I'm budgeting upto that for ultimate street comfort. Yes I've looked at the B12 Kit (B8 + Eibach) but again, the same quality concern would exist since the B8 is essentially a shortened B6.

[@7mpowerd]

What my Vett and c63S run.

[@fcpeuro-media]

Thats a nice combo.

[@ovalwingnut]

In a uber rush? jump to 2:00

[@KarolosAthens]

August """

[@rocketsurgeon11]

Would have liked to have seen how they inject the nitrogen (if any of these were gas filled). Also, VERY rare for a German company to run on a Sunday.

[@ghostwrench2292]

LOL. I thought that too! I thought Europeans only work like 4 days per week.

[@rocketsurgeon11]

@@ghostwrench2292 Nah, most work the typical 5 days. Germans in particular RARELY work on Sundays. Nothing is open, you can't do certain things...heck even semi-trucks aren't allowed to drive on highways unless they have a special permit.

[@fcpeuro-media]

@@rocketsurgeon11 We did have issues going to the store or eating out on Sundays during our trip! haha . We show the nitrogen filling process in the next video where we dive deep into the valving of their suspension.

[@rocketsurgeon11]

@@fcpeuro-media OK, I want to check that out. Thanks!

[@jamesr7335]

Now if they could just make the B6s not start rusting within a year.

[@fcpeuro-media]

We have a video coming out soon where we spoke with their RnD lab about some of their weather proofing and paint processes. May address some concerns!

[@maxheadroom224]

Yes. Unfortunately, the paint is chipping on mine only after 2 years, 10k miles.

[@bwhobackk]

The products are clearly really nice and made in a way I’ve come to expect fromGerman products. Really a shame however that in the US at least, trying to make use of their warranty is kind of an open joke in that I was told by multiple people to expect fulfillment and actual replacement to take “about three months.” Also, was told by us distributor they refuse to sell individual parts so unless I wanted rebuy the whole kit, I can’t expedite this. As an enthusiast who uses their car as a daily driver, it’s unacceptable to have to ride around on a defective blown shock unit for 90 days at least. As soon as I learned that was the case I became a customer of BC Racing instead.

[@fcpeuro-media]

We will bring that feedback to them from our end - always good to hear peoples experiences good and bad with companies we sell!

[@firstyaid7546]

In Deutschland sind diese Produkte mehr als doppelt so teuer als zb in den USA...Recht interessant oder? Da fragt man sich wie Bilstein die deutschen abzockt 😂

[@fcpeuro-media]

Wir fragen uns, warum das so ist, was solche Preisunterschiede verursachen würde, wenn das Produkt für die Deutschen inländisch und für uns importiert ist.

[@carefulsum]

The main damper body is already made in Asia and then shipped over to be finished built...what a lying company that's ripping off the customers.

[@stalesvindland5101]

And how is that lying and ripping off the customer? 🤔