So, had koni's warrantied and ready to put the car back together.
Compressing the rears isn't too hard, but putting the fronts together, one of the fronts feels about like the rears, the other is about 10% to 15% harder to push down - I don't have compression on one of my fronts blow, do I?
I think on sports, only rebound is ajustable. I cranked the dial, no change to compression, rebound travel value changed....
Well, I think my question has been answered. As I started mocking up assembly, getting ready to button up, with all components attached and ready to tighten up, the one unit extends all the way up through the tower and the other unit sits about half inch below spring tower.
Crud.
Twin-tubes really only work when upright, the process of shipping can be traumatic. Hold the problem shock upright and run it through the full stroke a few times. They also don't necessarily fully extend under their own power, as they don't have the same sort of internal pressure as monotubes. The Konis on my VW need a hard pull to get them to full extension.
So that Lee Grimes fella at Koni gave me the technical scoop - pretty much what Keith said. Lesson: Don't leave your Koni sports lying on the garage floor, stand them up-right. That and anything that can be done "by hand" tells nothing about units... If anyone wondered...