Harold Bawlzangya Racing

Taking apart and shortening eBay forks

Time to take the forks apart to shorten them.  The sticker on the forks indicated these were valved for an intermediate MX application.

The midvalves weren’t touched, the stacking/peening was still intact:

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The peening/staking was removed a little differently on one of the basevalve stems:

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But no signs of loctite:

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The pistons were surfaced, stock on the right:

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And the ICS springs were replaced with a lighter set:

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Factory spring on the top:

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And finally the stacks:

MX intermediate stack

All apart and ready to shorten the rods:

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Over the summer I bought a router lift and decided to use it for some of the steps instead of the table saw.  After wrapping the rods in painters tape to protect them, I used a straight bit to reduce the diameter of the rod to make cutting the threads easier:

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Both rods done.  Not that it matters, but this step certainly looks better compared to using the table saw:

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Threads are done:

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The only step where the table saw was used, cutting the rods down:

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Both rods shortened:

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Using the same straight bit, I cut the relief in the end of the rod.  No one will ever see it, but the router  cut looks a lot better than doing that on the table saw:

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Last step is drilling out the end for the needle:

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