New Gas Struts Won’t Compress? Easy to Fix

how to easy fix problem that new gas struts won't compress

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, resulting in difficulty closing the door. In such cases, you might suspect an issue with the struts’ quality or feel overwhelmed by its excessive strength. However, in most instances, the problem is caused by selecting a lifting pressure that is too high.

Apexstone 300N gas struts for heavy lid

How To Fix If Gas Springs Not Compress?

There are two methods to solve this issue, one is to adjust the gas struts mounting points, and another is to replace the gas struts with 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 is: Stroke (5.9 inch); Extended Length (15 inch); Compressed Length (9.1 inch).

A set of 300N 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 80lb/355N. In this scenario, we’ll assess the viability of installing a pair of 300N lift support gas springs. Given that the lid weight is well below 600N, our initial consideration is for a relatively horizontal installation.

In the accompanying diagram, we’ve identified four 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 to be 1/4 to 1/3 of the side length. 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.

Gas springs mounting point and installation guide, for apexstone 300N lift support gas struts

Once we have identified 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.

By using the identified installation points, we can calculate the required supporting force of gas struts using the formula F = G * y / (c * 2). In this formula, G = weight of the lid cover, y = 1/2 side length, and c is the distance from B to the bottom mounting point C, the measuring outcome is 4.5inch. Substituting these values in, the calculation becomes F1 = 335 * 1/2 * 25 / (4.5 * 2) = 465N. This outcome indicates that installing two lift support gas springs, each exerting a minimum force of 465 N, would ensure satisfactory lifting and support at the initially determined mounting point.

2) Easy Way to Adjust the Gas Strut Mounting Point

how-to-adjust-gas-struts-installing position or mounting points

However, each gas strut we used exerts a force of 300N, slightly less than the specified requirement of 465N. This slight difference in strength is not expected to adversely affect smooth operation. 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 away from the piano hinge to achieve a more vertical installation. Alternatively, if you find the current gas struts are too strong to close the door panel, consider a more horizontal installation by moving A closer to 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.

Let’s explore relocating the top mounting point to a position 2/5 of the side length, denoted as ‘a.’ This translates to a = 2/5 side length, which is 2/5 * 25 = 10 inches. After measuring, let’s denote ‘c’ as 6.6 inches. The required force for the gas struts in the new mounting points, denoted as F2, would be calculated as F2 = 335 * 12.5 / (6.6 * 2) = 317N.

Examining the results of two calculations, we can draw specific conclusions. ‘a’ should be set as 10 inch or more. For optimal operational effectiveness in door-opening and closing actions, it is advisable for ‘a’ to be equal to 10 inches. Consequently, we determine the value of ‘a’ to be 10 inches. Once the position is confirmed, drilling holes and installing gas struts with the rod down is all that is needed to complete the installation.

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!
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In summary, selecting the correct installation points for heavy-duty gas struts is crucial for project success. Our detailed example of the 300N15-inch gas strut demonstrates the process and benefits. 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!

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