Do you struggle with heavy lids on your truck toolbox, camper trailer, or storage bins? It is a common frustration that can lead to pinched fingers or strained backs during a weekend adventure.
Learning how to install a gas strut on a lid will completely change your DIY projects by providing controlled, hands-free movement. In this guide, we will cover everything from selecting the correct pressure to the final mounting steps for a professional finish.
By following this expert workflow, you will ensure your lids stay open when you need them and close securely without slamming. Let’s dive into the tools and techniques required to master this essential mechanical upgrade.
Understanding the Basics of Gas Struts
Before we pick up a drill, we need to understand what a gas strut actually is. Often called gas springs or lifters, these components use compressed nitrogen to provide force.
The internal pressure acts against a piston, which helps lift the weight of the lid. When you close the lid, you are essentially compressing that gas back into the cylinder for the next use.
In the world of off-roading and DIY builds, these are indispensable for gull-wing windows, heavy-duty tonneau covers, and custom storage drawers. They offer a level of convenience and safety that manual props simply cannot match.
The most important thing to remember is that struts come in various lengths and force ratings. Getting these specifications right is the difference between a lid that flies open and one that won’t stay up.
Essential Tools for Strut Installation
To do this job right, you need a few standard tools that most DIYers already have in their garage. Accuracy is key here, so do not skip the measuring phase.
- Power Drill with a set of high-quality metal or wood drill bits.
- Measuring Tape to determine the exact mounting points for the brackets.
- Pencil or Marker for highlighting where you need to drill.
- Screwdriver or Socket Set depending on the hardware provided with your struts.
- Safety Glasses to protect your eyes from shavings while drilling overhead.
- Masking Tape to mark positions without leaving permanent marks on your paint or finish.
Having a second person available is also highly recommended. Someone needs to hold the lid at the desired open angle while you take your measurements and mark the mounting holes.
If you are working alone, use a piece of timber or a prop rod to hold the lid securely. Safety should always be your first priority when working with heavy automotive or trailer components.
Calculating the Force and Length You Need
One of the biggest mistakes people make when learning how to install a gas strut on a lid is guessing the pressure. If the force is too high, you might bend your hinges or struggle to close the lid.
To find the right force, you first need to know the weight of the lid. You can use a bathroom scale and a piece of wood to weigh the lid at the edge where it opens.
A general rule of thumb for 90-degree openings is to choose a strut force that is roughly 60% of the lid’s weight when using two struts. For example, a 100lb lid would require two 60lb (approx. 270 Newton) struts.
Next, consider the “stroke” of the strut. This is the distance the rod can travel inside the cylinder. Your strut must have enough stroke to allow the lid to close fully without the strut “bottoming out.”
Measure the distance from your mounting point on the lid to the mounting point on the frame when the lid is open. Then, check that the compressed length of the strut is shorter than the distance between those points when the lid is closed.
how to install a gas strut on a lid: The Step-by-Step Process
Now that you have your parts and tools ready, it is time to begin the physical installation. Follow these steps carefully to ensure the geometry works perfectly on the first try.
Step 1: Determine the Mounting Geometry
Open your lid to the maximum height you want it to stay. Have your assistant hold it there or use a prop. Mark a point on the lid about one-third of the way from the hinge toward the opening edge.
This is usually the “sweet spot” for the upper mounting bracket. If you move it closer to the hinge, you need more force; moving it further away requires less force but a longer strut.
Step 2: Position the Frame Bracket
With the lid held open, hold your gas strut up to the lid’s mounting point. Extend the strut fully and see where the other end naturally falls on the frame or the box body.
Mark this spot on the frame. Ensure that there is enough clearance for the strut body to move through its arc without hitting the sides of the box or the lid itself.
Step 3: Drill and Mount the Brackets
Start by drilling pilot holes at your marked locations. If you are drilling into metal, use a center punch first to prevent the drill bit from walking across the surface.
Secure the ball-stud brackets using the provided screws or bolts. Make sure these are tight and flush against the surface to prevent any flexing under the pressure of the gas.
Step 4: Attach the Gas Strut
Most struts use a simple “click-on” ball and socket system. Snap the socket onto the ball stud on the lid first. Then, pivot the strut down to the frame bracket.
If the holes don’t align perfectly, you may need to compress the strut slightly or have your assistant lift the lid a bit higher. Once snapped into place, ensure the retaining clips are secure.
Step 5: Test the Operation
Slowly lower the lid for the first time. Watch the brackets and the strut body carefully. You want to make sure nothing is binding or rubbing as the lid closes.
If the lid won’t close all the way, your mounting points are likely too far apart. If the lid won’t stay open, you may need a strut with higher Newton force or to move the mounting point further from the hinge.
Orientation Matters: The Rod-Down Rule
A professional secret when mastering how to install a gas strut on a lid is the orientation of the rod. You should almost always install the strut with the rod pointing downward when the lid is closed.
Inside the cylinder, there is a small amount of oil used for lubrication and end-of-travel dampening. When the rod is down, the oil rests against the seals, keeping them moist and preventing gas leaks.
This simple trick can double the lifespan of your struts. It also ensures that the “soft-close” feature works correctly, preventing the lid from slamming at the very end of its travel.
In some off-road applications, like a vertical rear window on a canopy, the strut might be nearly horizontal. In these cases, try to maintain a slight downward tilt toward the rod end whenever possible.
Common Pitfalls to Avoid During Installation
Even experienced mechanics can run into trouble if they rush the process. One major pitfall is over-tightening the mounting hardware into thin material like fiberglass or thin-gauge aluminum.
If your mounting surface is thin, consider using a backing plate to distribute the load. The force exerted by a gas strut is concentrated on a very small area and can eventually rip the bracket out of the material.
Another error is choosing a strut that is exactly the length of the opening. You always want about 10-20mm of “dead space” left in the stroke when the lid is fully closed.
If the strut reaches its fully compressed state before the lid is closed, the pressure will likely bend your hinges or snap the mounting brackets. Always double-check your compressed measurements before drilling.
Finally, never attempt to open or disassemble a gas strut. They are under extreme pressure and can be very dangerous if punctured or cut. If a strut is failing, simply replace it with a new one.
Real-World Applications for Off-Roaders
For those of us at FatBoysOffroad, we know that gear needs to survive the vibrations of corrugated roads and extreme dust. Standard struts might fail prematurely in these environments.
If you are building a custom camping setup, look for stainless steel struts. These resist corrosion much better if you are frequently near the coast or driving through mud and water.
Consider the temperature as well. Gas struts lose some of their lifting force in freezing temperatures because the gas inside contracts. If you camp in the mountains, choose a slightly higher force rating.
For heavy rooftop tents or gull-wing doors that carry recovery gear, you might even consider locking gas struts. These have a mechanical shroud that slides over the rod to prevent accidental closing in high winds.
Maintenance and Long-Term Care
Once you have mastered how to install a gas strut on a lid, maintenance is minimal but important. Keep the chrome rods clean and free of grit, mud, or overspray from paint.
Avoid using heavy greases on the rod, as this actually attracts dust which can tear the internal seals. A simple wipe with a clean, dry cloth is usually all that is required.
If you notice the lid beginning to sag or it requires more effort to lift, the gas is likely escaping. Struts typically last 5-7 years depending on usage and environment, so keep an eye on their performance.
Periodically check the mounting bolts for tightness. Off-road vibrations are notorious for loosening hardware, and a loose bracket can lead to a sudden and unexpected lid closure.
Frequently Asked Questions About Gas Strut Installation
Can I use one strut instead of two?
While you can use a single strut for very light lids, using two is always better. Two struts prevent the lid from twisting or warping over time and provide a much smoother operation.
How do I know if my strut is too powerful?
If you have to put your full body weight on the lid to get it to close, or if the lid hinges look like they are under stress when closed, the force is too high. You should be able to close the lid with one hand and a firm push.
Is it difficult to learn how to install a gas strut on a lid?
Not at all! With basic tools and careful measurement, most DIYers can complete an installation in about an hour. The key is taking the time to plan the geometry before drilling your first hole.
What should I do if the lid doesn’t open far enough?
You may need to move the mounting points closer to the hinge. However, keep in mind that this increases the amount of force required to lift the lid, so you might need stronger struts to compensate.
Can I adjust the pressure in a gas strut?
Most standard struts are “fixed force.” However, you can buy adjustable force struts that come over-pressurized. These have a small valve that allows you to bleed off gas in short bursts until the lid moves exactly how you want it to.
Final Thoughts on Your DIY Project
Upgrading your vehicle or storage boxes with gas struts is one of the most rewarding DIY tasks you can tackle. It adds a touch of professionalism and utility to any build, making your gear much easier to access.
Remember that the secret to success lies in the preparation. Measure twice, consider the weight of your lid, and always install with the rod facing down to protect those vital seals.
Now that you know how to install a gas strut on a lid, you can apply these skills to everything from kitchen cabinets to heavy-duty trailer ramps. It is a versatile skill that every off-roader and DIY mechanic should have in their arsenal.
Take your time, stay safe, and enjoy the convenience of a perfectly balanced lid. Happy building, and we will see you out on the trails!
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