Tubular Travials

[Burns]

I am refreshing a set of 35 mm Ceriani forks. Unfortunately the task is not refreshing me.

The fork tubes have internal reinforcing tubes which makes it necessary to remove the dampner innards from the bottom. There is an alumimum plug with a hole in it for the dampner rod at the bottom of each tube. They are secured by circlips. The plugs have to come out to get the dampner innards out of the fork tube.

One of them came right out with no promblem.

The other one didn't.

There is not much to grab.

The outer tube is steel and the plug is aluminum, so I'm thinking that the co-effecients of expansion are working against me using heat a la iron sleeves in aluminum cylinders.

Any suggestions?

[grizld1]

Drill, tap, thread screw into plug, and pull; attach locking pliers and apply impaction if need be. When finished, seal the hole in the plug with silicone so you can dig it out and repeat the exercise next time you need to break down the forks.

[Burns]

There is a hole in the middle of this collar/plug but the dampner rod lives there (the plug is what keeps it in the tube) so I can't go that route (I'd be drilling into the dampner)

The other plug pretty much just fell out, so there can't be all that much holding this one.

I tried a bearing puller but there is just not much to grab and the bearing puller legs push the plug into the tube when they spread, which just tightens up the plug more.

I'm thinking maybe to spot weld a bit of aluminum tube to the plug and fashion a sort of slide hammer to tap it out.

[Burns]

I got that collar out.

I took a 1//2" drive socket with an o.d. that was close to the i.d. of the collar. With a grinding wheel I "turned" the socket so it fit down into the collar about 1/4" and had a bevel fit against it. I smeared JB weld on the socket and snugged it up to the collar being sure not to let any of the JB get on the fork tube.

I let it cure overnight and this morning I twisted the rascal free with a ratchet.

Mission accomplished.

[grizld1]

So it's true, what they say about age and treachery--congrats, Burns!

[Burns]

thanks for you kind (?) words Griz.

I think part of the "joy" of messing with old motorcycles is dealing with the frustrations that arise when what should be a simple little task turns into a PROJECT. Well, at least for the projects that you get solved!

Heck, anybody can BUY a motorcycle with no "challenges" between you and putting it on the road.