I’ve changed struts on a handful of cars in the past and have never had as much trouble as this car has given me. I’m here to seek gear head community feedback from multiple perspectives rather than pay some mechanic for rework and end up with no positive results since this problem is probably this guy capable. I figure I just need guidance and some expertise.
Also, this is the wife’s car so Murphey’s Law apparently is aware of conditional needs for things to go smooth and thus presented me with just the opposite since I have nothing better to do than ponder over strange noises coming from cars 
Both front struts and rear shocks were replaced. I didn’t notice any rubber rot in the upper strut mount so I reused them both. I also renewed the grease in both upper bearings and cleaned any outstanding dust that had bonded to escaping grease. I did have one particular problem with one of the two struts that was 100% my fault, but seemed harmless at the time. I used an pneumatic impact tool to break the nuts from the old struts free and also used the same tool to place the new strut’s spring retention nut back on. I found that the material of the strut or the nut were not as strong as previous struts I’ve worked with and I ended up stripping the nut. I promptly ground down another nut to reduce its size and placed it on top of the stripped nut to ensure strength and prevent the possibility of slipping off. Then I expanded the spring and installed both struts.
I can speculate on what the problem is, but I’ll save that for last. These are the symptoms. Hitting of smaller bumps and travelling straight reveals nothing is wrong. Hitting really large bumps while turning slightly or semi-sharply or turning sharply then the game changes. At about 70 or 80% full turn travel the wheel will suddenly jerk about 2 to 5 degrees either multiple times or one large jerk into the direction the car was being turned and makes a localized to front of car rubber on rubber kind of binding noise. It happens on both sides of the front of the vehicle and is almost always guaranteed in sharp turns. The condition doesn’t improve or get worse if the car is in motion or sitting idle. Turning the wheel under any condition produces the same sound and jerking of the tire.
My suspiscion due to visually viewing the strange problem is that someting is binding in the strut, but I’m puzzled as to what it could be. In the upper mount there appeared not to be any rubber to rubber looking joints. The only thing I can really think of is that the upper mount is torqued down to tight, but even that doesn’t make sense to me since the bolts only keep the mount in place and really shouldn’t cause any binding in my opinion.
Could it be that I applied to much torque in the upper nut that keeps the strut in contact with the spring and upper mount bearing? I wasn’t aware that this could be possible since the core of the upper mount bearing is a solid piece of metal and void of rubber.
Also, if anyone has advice for getting out stripped nuts in a recessed environment please let me know. A dremel probably won’t work in this case. I’m thinking maybe if I need to cut it out I can use an pneumatic chissel like cutting tool.