New Gas Struts Won’t Compress? Easy to Fix

Are you facing a problem with newly purchased heavy duty lift gas struts that won’t compress? If you’re encountering any of the following issues with your new lift support gas springs, read on for assistance:
# They are excessively rigid for my application.
# Despite applying significant force, I cannot move the piston rod.
# The struts are too strong for any hood.
# The gas struts feel as hard as rocks.
# They do not compress at all.
# Maybe more…
In summary, the inability to compress the heavy duty gas struts may prevent the lid from closing, leaving it in a supported and open position.

What Leads To The Not Compressed Gas Struts?

Typically, there are two potential reasons:
1. Overextension
2. The pressure is too high for the strut to compress under the weight of the door.

Lift gas struts for heavy lids with a force of 300N or more apply significant pressure, making manual compression impossible. Even with correct installation, lighter lids can not compress the lift support gas struts, leading to challenges in closing the door. In such cases, you might suspect an issue with the struts’ quality or feel overwhelmed by its excessive strength. However, in many cases, the issue arises from selecting a lifting pressure that exceeds the necessary level.

How To Fix If Gas Springs Not Compress？

There are two methods to solve this issue:

• Adjust Gas Strut Mounting Points
• Replace Gas Struts With Correct Pressure.

This article will elaborate on the methods for adjusting the mounting points of gas struts. At the end of the article, we will tell you how to find the gas strut lift support replacement with the correct pressure.

1. Correct Installation Method and Adjustment for Mounting Point

In this guide, we’ll use a pair of 15-inch lift support gas struts with a force of 300N as an example to explain the correct installation method and how to adjust the installation point.
The specification of these 15″ gas struts is: Force (150N); Stroke (5.9 inch); Extended Length (15 inch); and Compressed Length (9.1 inch).

A set of 300N heavy duty gas springs is theoretically capable of efficiently lifting a lid weighing up to 600N, we should not underestimate the pressure within the cylinder. Now, let’s delve into the installation process for gas shocks and discuss how to adjust the installation points for optimal performance. Let’s break down each step.

1) Correct Installation Method for High Pressure Lift Struts

Let’s take an example of a lid with a side length of 25 inches and a weight of 45lb (200N). In this scenario, we’ll assess the viability of installing a pair of 300N lift support gas springs.

① Identified Several Crucial Points

A (top installation point)
B (positioned along the extension line of the piano hinge, with AB perpendicular to the piano hinge)
C (bottom installation point)
A1 (position of A when the lid is closed)
C1( presumed bottom mounting point, A1C1= d= compressed length =9.1inches)
a (distance from A to B)
b (distance from A1 to C)
c (distance from B to the bottom mounting point C)
d (gas struts compressed length)
Typically, the distance from the upper installation point to the piano hinge “a” is marked 1/3 of the side length, suggested to be 8.3 inches. However, this is not set in stone and can be adjusted as needed based on the specific circumstances. Our primary objective is to achieve improved outcomes, with a focus on ensuring the lid can be smoothly closed during the adjustment process.

② Pre-Determine the Value of Mounting Point

First, identify the top installation point A. Assuming the value of “a” is 1/3 of the side length, equivalent to 8.3 inches.
Then, adjust the lid cover to the desired opening angle, such as 90°.
Next, determine the bottom installation point C. To ensure the lid closes securely, confirm that, when the door is shut, the distance from the top mounting point A1 to the bottom installation point C (b) should surpass the compressed length of the gas struts, which means that the length of “b” should be greater than “d” (9.1inch).
If this condition is satisfied, and the desired opening angle is achieved, we can establish the position of the bottom installation point.

③ Using Calculating Formula to Know Whether Adjustment is Needed

Once installation points are determined, we can calculate the necessary gas strut force using the formula from the article “How to Calculate Gas Strut Position“: F = G * y / (c * 2), where F represents force, G is the weight of the lid cover, y denotes 1/2 side length, and c is the distance from B to the bottom mounting point C,  is recommended at approximately 20% of the panel length. So, c is 5 inches.
Substituting all values in, the calculation becomes F1 = 200 * 1/2 * 25 / (5 * 2) = 250N. This outcome indicates that installing two lift support gas springs, each exerting a minimum force of 250 N, would ensure satisfactory lifting and support at the initially determined mounting point.

However, each gas strut we used exerts a force of 300N, slightly larger than the specified requirement of 250N, which means that we may have challenges in compressing the door. So, we need to adjust the mounting point for easier closing.

2) Easy Way to Adjust the Gas Strut Mounting Point

This slight difference in strength is not expected to adversely affect smooth operation.

① The Rule for Adjustment

However, if closing the lid proves to be challenging after pre-installation, a minor adjustment is necessary, the adjusting method is to move the top installation point A closer to the piano hinge to achieve a more horizontal installation.
Alternatively, if you find the current gas struts are too weak to close the door panel, consider a more horizontal installation by moving A away from the piano hinge.
Regardless of the adjustment method chosen, it is essential to ensure that the door can close properly. This entails confirming that the distance from A1C exceeds the compressed length (d).

② Practice the Adjustment

For a horizontal setup, let’s consider relocating the top mounting point to a position that is one-quarter of the side length, labeled as ‘a.’ This means a = 1/4 side length, which equals 6.25 inches (since 1/4 of 25 is 6.25 inches). Since the distance from the piano hinge to the spring is shorter, let’s designate ‘c’ as 16% of the panel length, equivalent to 4 inches. The required force for the gas struts in the new mounting points, labeled as F2, can be calculated as F2 = (200 * 25* 1/2) / (4 * 2), resulting in 312.5N.

Analyzing two calculations yields precise conclusions: ‘a’ should ideally be 6.3 inches rather than 8.33″, ensuring optimal efficiency in door operations. Upon confirming the mounting position, the installation is swiftly accomplished by drilling holes and fitting gas struts with the Rod Down.

If you find effortlessly lifting and closing the chest door after installation, it indicates a successful adjustment. Congratulations, buddy!

2. Replace the Support Struts

If adjusting the installation points fails to enable the lift support struts to compress, it may be due to overextension or the selected pressure far exceeding the necessary lift force. In either scenario, it is advisable to replace the lift support shocks with the appropriate pressure. This ensures not only safety during use but also provides assistance and convenience when operating doors with substantial weight.

If you’re looking to replace the gas struts, you can explore the detailed guide in the following articles, each tailored to different projects. Identify the one that aligns with your needs and commence your learning journey right now!
→ Easy Way to Fix SentrySafe Gun Safe Strut Failure
→ How to Replace Hood Struts? How I Saved $300?
→ How to quickly install soft close gas springs in 10 min?
→ How to adjust soft close hinges for toy box？
→ RV gas springs mounting guide

In summary, selecting the correct installation points for heavy-duty gas struts is crucial for project success. Our detailed example of the 300N 15-inch gas strut demonstrates the adjustment process easily. If you find this information useful, share it on your social media to assist others. Besides, explore our premium gas struts online, where you can unlock an exclusive 10% discount today! Simply enter the code “NEW” at checkout. Don’t miss out on this special offer – place your order today for top-notch quality and savings!