Subject: RE: Fork Assembly Problem
Author: Zerhackermann
Date: Feb 19, 2002, 10:40 AM
Post ID: 1709676006
TO get mine together I had a tool made. The long t handle doodad looked
far too flimsy and I was going to remove the whole front end anyhow so
drawing the tube up with the front en in situ wasn't necessary. My
buddy, a machinist took an old tonti frame fork tube plug (same threads)
and turned the diameter of the top dow to it will fit throught the clamp
and top plate. Then a hole was drilled to accept a very course thread
insert. He also made a cup about 1.5" deep that is bigger than the clamp
holes. Two hardened monster allen bolts complete the kit.
To disassemble the plug goes into the top of the tube. Because the
threads on the plug are aluminum and fine, you make sure it screws all
the way in. then the short allen bolt is put into the plug. A big gear
puller it put on the top plate with the center driver into the socket of
the allen bolt. The arms of the puller must grab the insert on the top
clamp that actually holds the tube. Otherwise it can warp the top plate.
A few turns, a few taps and it popped loose a 30 year old paint sealed
taper fit with a loud bang.
To reassemble I used latex gloves to grip the tube and get it up to
where I could reach. I also did this with the whole front end off the
bike. Makes it easier. Then I used my tool to pull the tops up enough
into the top clamp to have a sticky fit and tightened the bottom clamp.
Fit the front to the bike. Loosen the bottom clamp and use the tool to
pull the top up the rest of the way.
The pull part works like the removal part. Put the plug in the tube top.
This is where a design flaw comes into play. It is tough to get the plug
screwed in all the way. Hindsight says cut a slot for a wide screwdriver
or some such. I just used the short bolt and gave it a hard twist left
to remove it without unscrewing the plug. With the plug in place, put
the cup on open end up, put the log (or short) bolt through the hole in
the cup and use an allen key to draw the caap and tube up to the cup.
Then remove the cup, put it on open side down and repeat until the fork
tube top is level with the top clamp insert.
Ba da bing.
It takes less time than it does to describe if all goes well.
I think you could use the main seal seating cup tool as the cup in this
manner.
Should be a fairly cheap job to take to a machinist if you have the
Tonti tube plug handy. No particular reason it has to be a tonti plug,
they just seem to be cheaper and easier to get.
The brake rod idea sounds interesting. I'll see if I can find my spare
and another t and loop fork cap to check the idea. Seems like it would
work. Sort of like using the engine mount bolts as a clutch centering
tool. Blew my mind when I saw that.
-----Original Message-----
From: David Whalen [mailto:haircutti-@yahoo.com]
Sent: Tuesday, February 19, 2002 7:59 AM
To: Loopfram-@topica.com
Subject: RE: Fork Assembly Problem
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Thanks Fred and Kevin,
The fork tube has not fallen too far. I can still put
the big nut on it. I just cant get the top triple
plate back on and the bolt through it. Suppose I
should loosen the lower fork clamps, then perhaps I
tie some strong wire around the nut, jack up the bike,
and cinch the wire around an exposed roof beam and
slowly and carefully let the bike hang by the wire at
the nut. Do you think that would work?
dw