Or if rods are used often? I have noticed that if I extend my rods to +60mm then go to off-road height, the front struts will top out on the stops on undulating sand tracks. This must not be good for the stops in the long term...
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Semi temporary repair done, I filled the gouge with epoxy metal putty, filed back smooth and then stuck a 4.5mm thick rubber over the area to help give it some protection.
Also ground / filed the sharp edge on the arm that dug in. Hopefully that will prolong the replacement of the whole strut as it wasn't leaking any air.
https://www.aulro.com/afvb/images/im...2017/08/39.jpg
https://www.aulro.com/afvb/images/im...2017/08/40.jpg
I'm not confident that the repair will really achieve anything. The issue is the over-extension and the effect this has on other bushes, cv's, sensor arm, etc rather than the cosmetic damage to the outer case. I would not be doing anything that causes the strut to top out (ie driving off road) until you replace them. I think it was BobD that had this happen to him resulting in a pretty expensive repair bill replacing a whole heap of bushes. Will be even worse if your CV lets go as well.
After spending heaps on my Power Steering last week I can't afford to replace both front struts, I thought about a limiting strap of some sorts but it would be dangerous, all my bushes are 100% while I am going 4wding this weekend I will closely monitor the strut etc.