Sorry to say, but if the chrome is gone unfortunately the shock is toast. This isn't my opinion, it's Bilsteins. I sent a similar set in for rebuilding and they refused to touch the fronts. It may last a while, it may not, but sooner or later the section that's missing the chrome will kill the seal.
So the roughness of the worn spot will wear the seal over time? Could I just polish that with a few different grad sanding bits to make it as smooth as the rest of the surface therefore eliminating the issue?
Do a Google search for Bilstein service- I'm not sure they have a phone #. For the rebuild service, you just ship the shocks to them and they eventually call you to discuss the rebuild and give you final pricing.
Anyway, according to them the worn spot will rust if the car sits for any length of time, and that (and/or the edges of the chrome) will eventually kill the seal. There's not much you can do about it per Bilstein. I asked if they could re-chrome the piston and they said that they didn't offer that as part of their repair/rebuild service- if one came in under warranty they'd just replace it with a new one. They just sold me another set of fronts and revalved them.
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