Front Fork Rebuild - WANTED - ASSISTANCE IN HOUSTON!

[Klavdy]

[Splash]

I made a fork cap/damper rod tool from a M18 nut and a chainsaw file. I noticed the hole was close to the size of a 1/2" drive; I make a few passes with the chainsaw file, holding the nut upright on my workbench, about halfway through the threads. I then turned it 180 and did the same on the other side. Holding it on point 90 from the first filings I did 2 more grooves such that I had 4 roughly 90 degrees apart inside the threaded hole. My 1/2" socket drive fit in the grooves, some duct tape around the drive provided a friction fit that held the nut in place. A couple extensions added and I was able to torque out the dampers quite easily, without welding. The nut cost me $1.40 at Ace Hardware, and I already had a chainsaw file. No welding needed! Forks rebuilt!!

It was awful in there, don't think the oil had been changed in a long time....

[Scooterbob]

Duct tape and a chain saw file.....I can't wait for the photos. 

[Mark Olson]

That's the way to do it. duct tape is your friend.

[carsick]

I think Splash is of New Zealand descent. I am envious I didn't come up with that solution first.
Doug