what forks to use

[(F5)]

Thanks. Yeah the steering damper will fit fine I'll just drill some new holes and make some spacers that also countersink to the old ones.

I've made some plastic blocks that will bolt and tack to the clamps once recreated in ally. Don't know why I thought it would be so hard. Even the guard looks like it can be re-drilled.

[(F5)]

Hmm, well I've plunged ahead. Here are the spacers I've turned up to go from the 25mm GG axle to the 20mm YZ one:

The bearings from old GG & the only ones that are commonly available for a 42x20 size are 12mm wide (6004) as opposed to the skinny 9mm ones for the 25mm axle. This means the seal will poke out about 3mm which I suppose should be ok.

I've just roughed the outer spacers a little oversize and will skim the last mm or so once I have it ready to bold together with the wheel & clamps. I will then take the final skim from the outer to leave the lip that retains them in the seal (can't hold onto the spacer to cut it down if I do that first).

Then I just have to push out the steering races out (the bearing was indeed past it) and I'm dropping off the triple to my weldy guy. He has some thick plate ally I believe, will post pics when done. Will bolt up from bottom & be tacked to the old stops.

[(F5)]

YZ Clamps with blocks added. So there's a bolt from the bottom which is the main strength + they are butted up against the curved clamp. they are also tacked to the old stops & a bit at the bottom. They bear on the frame with a wide contact patch, I might have to face the surface so they hit evenly but there is plenty of meat.

Have the races in the freezer so might slam those in tonight, press on the bearings & this could go together.

[Jakobi]

Looks good F5. What year model forks did you end u running with?

[(F5)]

06 yz250. SSS. They're in but there's half a dozen jobs to do and bed is calling. Post pictures tomorrow.

[nknudsen]

Nice work F5. I had thoughts of doing mine that way too.

[(F5)]

Here's the pics; steering stop is almost against frame, I turned the bars so I could get the shot. You can see the frame paint damage where the old stops hit.

And the finished item. . ..Save for the fact the bar clamps are just sitting there, there are no spacers in the axle, the brake is hanging there & the guard is held on with a bungy.

But I've noticed the right fork is weeping again. I really want to ride it so I can decide if it needs different springs or valving rather than pull them down for seals & have to do it again straight away. I'll put in some old brake pads just in case the seal goes. They've been sitting so often that clears up. . .

[(F5)]

Well all stitched up, spacers done etc. Those fork guards will need replacing they look dreadful (worse than picture).

pump it up & down a bunch.


Aww idda maka groan man wheap.

nah those seals are shot. I don't have the tools or time to change them before the weekend. Might pop them down to the local & try my luck.

There's also a bit more stiction than I was expecting. One of the fork guards is rubbing & it was a bit better when I popped down before breakfast (having thought about it while awake last night) to loosen the axle.

Theoretically with a floating axle design as long as you don't tighten the right axle clamp till last after some bouncing it will centre. But I did notice some flaring on the axle head, probably from a butcher with a big hammer. I'll turn it in the lathe to ensure its parallel.

[(F5)]

Well I've taken the flare off the axle. Its pretty straight, within 1/2mm, might give it a tap, but I've dropped the forks off. Weds or thurs. Bugger. Next ride day is end of the month.

[Jakobi]

F5 - wanna measure your fork lug offset? Did you take the effect of this into account?