Rusty Fork Tube

[Nessism]

Ditch the anti-dive.

Remove plumbing and actuator and make some plates like these...

[JEEPRUSTY]

Give me a tank of gas my truck and a reason to go to the manor of Elsie Wayne and I shall rule the world!!!

Anyway if you are totally stuck I have some viable forks 3 hours away.

[flatty_420]

Give me a tank of gas my truck and a reason to go to the manor of Elsie Wayne and I shall rule the world!!!

Anyway if you are totally stuck I have some viable forks 3 hours away.

Sounds good...thanks for the backup plan.

[flatty_420]

Ditch the anti-dive.

Remove plumbing and actuator and make some plates like these...

Not sure I could make those....looks like I would need a milling machine for that trough on the inside. Maybe using the existing modulator valve and replacing the hose to the caliper with a plug?

[spyug]

Maybe using the existing modulator valve and replacing the hose to the caliper with a plug?

That's exactly what you can do. Remove the hose between the modulator and the caliper. On the modulator insert a bolt or plug of somekind (epoxy putty if you don't plan on using them ever again. On the caliper side, cut off the banjo from the hose close to the body of the banjo and weld the cut closed closed. Put the banjo back on the fitting to the caliper ( don't forget the crush washers). Re fill the master and bleed the brakes. Job done.

Those existing forks look like a pain, if I were you, I'd take Jeep up on his offer and switch to the forks with screw in caps. Lots easier to work with.

Good luck with it.

Spyug

[flatty_420]

Those existing forks look like a pain, if I were you, I'd take Jeep up on his offer and switch to the forks with screw in caps. Lots easier to work with.

I am seriously considering it. I will soak with Evaporust first and then PB and try again. If I can't do anything with them after that, JEEP will probably be getting a PM.

[flatty_420]

Here's what they look like after 24 hrs of Evaporust....stuff works nicely. PB Blaster is in there now and I'll see what I can do with them tomorrow night hopefully.

[rustybronco]

I'm thinking low pressure air through the port (20psi), place socket on the cap, tap socket, soak, air pressure, tap... sort of a tap down, push up, tap down, push up on it type of affair.

[Nessism]

Wow, those caps are pitted all to crap. Water must have sat on top of them for a LONG time.

BTW, I made those blank off caps using nothing but a hack saw, drill press, and grinding burr in a die grinder (you could use a drill). It ain't rocket science, just hard work. Looks way cleaner to cap them than just put a plug in the port.

[flatty_420]

Alrighty, I am done with these forks. I cannot get these caps to budge no matter what I try. 24 hours of Evaporust soak....another 24 hours of PB Blaster. They would not budge AT ALL. I eventually got to the point where I figured if I cannot get the caps to budge I might as well try drilling a hole in the cap, tapping it, and putting a bolt in to give me something to pull on while working them...what the heck I can't use them this way. Bolt ended up breaking off and still the cap would not move AT ALL.
I give up on these forks...I have a possible line on another parts bike sitting in a barn not too far away, but if that does not pan out....JEEPRUSTY, I will be contacting you.

[JEEPRUSTY]

I do not know which material would have the greatest expansion coefficient but maybe a really hot heat gun would help.

You might also check to see if there is not a second cicclip.

Are the plugs pushed completely in?

[flatty_420]

I do not know which material would have the greatest expansion coefficient but maybe a really hot heat gun would help.

You might also check to see if there is not a second cicclip.

Are the plugs pushed completely in?

Yes, they are pushed completely in... they will not move up or down.

[JEEPRUSTY]

Add air till they pop off?

[flatty_420]

Nope, I did not use air. I had a large pair of vise grips on the bolt that i put into the tapped hole and was pulling and wiggling for all I was worth. Then I was prying with a very large screwdriver on the vice grips....far more pressure than the air could have put on the cap.

[hampshirehog]

You need to give them a real good smack with a punch or old socket extension bar. Then smack the fork bottoms with a mallet (so that the spring does the pushing for you). Just keep doing that over and over - I have done loads worse than these (with our old salty roads you just get used to it) - they'll come out.