I installed turbo bars on my car and replaced the strut inserts with Sachs Advantage. The top large center nut, the three nuts that hold the strut mount at the top of the strut tower, the gland nut, and all the ball joint nuts are tight. The new strut insert is exactly the same length as the old one. The gland nut is not bottomed out and has 2-3 threads still showing. Everything is tight, but I still get a very noticeable clunk on the driver's side when going over bumps, like the little reflector bumps that divide the lanes in the road. I did not spin the main strut shaft when installing the large top nut, but used an effective counterhold tool. The Turbo bars have new bushings and all fasteners are tight. I'm out of ideas. Bad strut insert? Does this happen often? Any other things to try, before I replace the new strut insert with a known quiet one to pin this down.
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Thanks everyone for all the help, Doug C. 81 242 Brick Off Blocks, turbo bars and wheels, M46; 86 244, B230, 155k , auto; 81 242 Turbo, intercooled, M46, 122k; 93 245, B230, M47, 153K.