I am going to give the existing base valves a try using some shim stacks I found on the Cafe Husky forums posted by some of the more experienced guys.
I posted them in motopsycho's thread. They are pretty standard and are similar to other nice working forks I have seen.
Terry Hay has posted that these base valves are capable of providing good results and are not really too restrictive. He says the shim stacks are actually more restrictive than the ports. I can believe that because it looks that way to me too. I have not actually done the calculations, but Terry is one of the best tuners on the planet, so I trust his judgment.
Lots of other things can make the fork harsh besides base valve port size. For example I hear that rebound needs to be increased on these forks to reduce harshness feeling in your hands when the forks rebound too quickly.
Will see how this works out.
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