Dangerous Hidden Fork Damage

[Eli69]

I was rebuilding some forks from an old GS1000 part bike when I realized that one of the tubes was sticking when fully depressed. It took some time to find the problem. Very subtle damage but a dangerous situation if the tube had gotten stuck while riding.





Scrap pile for this one.

[hannibal]

It looks like just a scrape on the outside but it was enough to leave a dent on the inside??

[Eli69]

It looks like just a scrape on the outside but it was enough to leave a dent on the inside??

eggzactly.....

[sam000lee]

Wow that's crazy. Thanks for sharing

[Brendan W]

Looks like it was used to hammer something with fine threads.

[GregT]

I've struck that myself on a set of non Suzuki forks. These ones were pretty well non replaceable so I made up an extended honing tool and went at it quietly until I had a parallel bore and forks moving smoothly. It was a restoration and the sliders were a thinwall forging...

[bwringer]

Huh. That's a new one on me. Never really stopped to ponder how thin those casting walls are.

Thanks for posting -- it's always good to learn something new.

[Cipher]

as an aeroplane tech once said to our flight class
aluminum does not forgive

[BigD_83]

Looks like it was clamped really hard in a vise without any soft, supporting, material...