I think I ruined my forks

Norcoastal

Norcoastal

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Aug 21, 2016
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I am rebuilding my 1964 Atlas Roadholders forks. I bought new fork tubes, new bearings and bushings and the bronze bushings wouldn’t go on the new fork tubes. I assumed that there were possibly high spots so I did some fine sanding. I got them to go over one of the tubes, but it was a little tight. I oiled up the tubes and bushing really well.

When it came time to rebuild the fork tubes and bushing, I installed the bushing on the fork tube and hammered it into the lower fork leg. Now the tube is frozen in the lower leg and I can’t get it out.

I’ve been reading a bunch here and it appears that the tolerances are all over the place and not consistent, now I can’t get the tube out. I put a channel lock on the tube, and it spins reluctantly, but I still can’t get it out.

And if I do get it out, I’ll need to buy new oil seals because I destroyed the ones I bought, but I’ll still be in the same boat. There’s a guy on eBay that’s selling new seals and used bushings and I’m considering that. But the fork tubes may be shot because I have some nicks on it form the channel locks.

My biggest concern now is getting the fork tube out of the lower slider

Any advice?
 
Sometimes heat can be your friend when taking apart tight assemblies - especially if it involves steel parts (e.g. bearings, fork tubes, etc.) fitted into aluminum housings (crank cases, lower fork legs, etc.). Heat the ever loving crap out of that fork lower, secure it tightly somehow, and give the tube a honkin good yank. (Careful! It might be HOT.)
 
Norcoastal said:
I am rebuilding my 1964 Atlas Roadholders forks. I bought new fork tubes, new bearings and bushings and the bronze bushings wouldn’t go on the new fork tubes. I assumed that there were possibly high spots so I did some fine sanding. I got them to go over one of the tubes, but it was a little tight. I oiled up the tubes and bushing really well.

When it came time to rebuild the fork tubes and bushing, I installed the bushing on the fork tube and hammered it into the lower fork leg. Now the tube is frozen in the lower leg and I can’t get it out.

I’ve been reading a bunch here and it appears that the tolerances are all over the place and not consistent, now I can’t get the tube out. I put a channel lock on the tube, and it spins reluctantly, but I still can’t get it out.

And if I do get it out, I’ll need to buy new oil seals because I destroyed the ones I bought, but I’ll still be in the same boat. There’s a guy on eBay that’s selling new seals and used bushings and I’m considering that. But the fork tubes may be shot because I have some nicks on it form the channel locks.

My biggest concern now is getting the fork tube out of the lower slider

Any advice?
Click to expand...
Once you go back to assembling, the upper bushings may need light tapping to get them in but certainly no hammering and there's no point in putting them in at all if the tube does not slide in the bushing. Sounds like someone sold you junk bushings, tubes, or both. This is generally not a difficult task.
 
I think I’ve determined that it’s the bronze bushings and not the fork tubes. I bought the fork tubes from Greg at Von Licht Cycles in PA. I’ve been to his warehouse, Greg is the real deal. These NOS Norton tubes are really hard steel. Then I tried to sand them, it barely left a mark. I tried the other lose bushing into the other fork leg and it doesn’t go in. I’d need to hammer it hard and I don’t want to do that. So the bushings have are not true. I’m going to order a set of used ones. At least I’m confident of the fit.
 
Norcoastal said:
I think I’ve determined that it’s the bronze bushings and not the fork tubes. I bought the fork tubes from Greg at Von Licht Cycles in PA. I’ve been to his warehouse, Greg is the real deal. These NOS Norton tubes are really hard steel. Then I tried to sand them, it barely left a mark. I tried the other lose bushing into the other fork leg and it doesn’t go in. I’d need to hammer it hard and I don’t want to do that. So the bushings have are not true. I’m going to order a set of used ones. At least I’m confident of the fit.
Click to expand...
Normally, fork tubes are hard chrome plated and sanding through that would ruin them.
 
Put the top mounting bolts with a washer in the top of the fork tube, clamp it in a vice using the washer to stop the tube from moving down and then with the axle through the bottom fork leg use a mallet to knock the leg off the tube. Use a bit of heat around the area where the bushes are mounted and you should be fine.
 

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