Fork problem

[Phil C]

Evening everyone.

Not going very well at the moment. 

This afternoon I started refitting the (Heavyweight) forks on my 1965 B40F. I'm new to this. I fitted the first one, drawing it up into the taper with the tool (see photo.) That went okay. I tightened the pinch bolt, removed the tool, and moved on to the next fork. This is when things stopped going okay. Using the tool, I turned the nut until it tightened. I was hoping and expecting to find the fork nicely up at the top of the taper where the end cap would fit. But it wasn't. It was about an inch down, with part of the tool still threaded into it (see photo) and the small nut (which holds that part of the tool) no longer on the tool. Missing. AWOL. So I thought I'd better take the fork out of the yoke and investigate. But the fork won't come out, and I don't know why. I wonder if it's something to do with the little nut and washer, which must have fallen in there somewhere (but inside the fork, I'd have thought, but not sure) or whether I just need to put a drift down the hole and give it a wallop. I'm guessing that from a distance no-one will be able to know what's up, but if anyone has any ideas I'd be very grateful.

Phil

[EDDIE SIMPSON]

hi phil,
the only thing that could be holding your fork is the bottom yoke .so maybe the pinch bolt clamp needs a careful  spread with a chisel or large screw driver. 
screw the tool in and whack the top of the tool to release the fork . i would check the bottom yoke for a burr and try the fork fit without the spring to check the fit. the stantion may be burred where it goes into the bottom yoke.

[Phil C]

Thanks Eddie. The tool for whacking is down there in the stanchion (see photo). But anyway, yes, thanks, I'll try a screwdriver in the gap, and use a drift and hammer to give it a wallop. Don't know where the small nut and washer are - somewhere in there, I guess.

Phil

[chaz]

I wouldnt worry about the tool, Ive done hundreds of forks, British, mx, superbikes etc and never used a special tool.
As Eddie says, carefully ease a screwdriver into the slot to slightly spread the bottom gap. As its just gone in it should come out easy. HAve another cuppa and start with a clear mind.

its a bit like piston clamps, Ive never been able to get on with them so never use them, but have built many engines without. yet, others seem to get on with them.

[idie]

I can't get on with ring clamps either. I find them to long, I use a strip of alloy wide enough to cover the rings held tightish by a jubilee clip.

[Spaceman]

Thanks Eddie. The tool for whacking is down there in the stanchion (see photo). But anyway, yes, thanks, I'll try a screwdriver in the gap, and use a drift and hammer to give it a wallop. Don't know where the small nut and washer are - somewhere in there, I guess.

Phil

I would not try to drift out the stanchion except with the special tool or the top nut in place because it is all too easy to damage the thread - once the thread is damaged, it is very difficult to repair it. As said, the fork can only be being held by the bottom yoke. If you push up on the lower leg to slightly compress the spring, a sharp downwards movement should then dislodge the stanchion - or force a screwdriver into the lower yoke slot to loosen its grip.

[Phil C]

Yes, thanks spaceman, I wouldn't hit the top of the stanchion without the threaded tool screwed into it, but it is, as you can see on the photo, so I'll give it a wallop (with a softer metal drift) after gently prising the slot. The threaded tool should support the threaded tube. I'm just hoping there's nothing else preventing it coming free and that the wallop might cause damage. Oh well, we'll see. I expect the advice from this forum will be spot on as usual.

I'm keen to have a go at it but can't even get to it at the moment because the garage is stuffed full of stuff from the garden being stowed away from the high winds.

I think chaz's advice about having a cup of tea when things aren't going well is very sound. I remember reading a similar thing in a book about classic bike restoration. Taking time out to review the situation with a calm, clear mind is, I think, time well spent.

I'll let you know how I get on. (Bet you can hardly contain your excitement!) 

Phil

[chaz]

I think chaz's advice about having a cup of tea when things aren't going well is very sound. I remember reading a similar thing in a book about classic bike restoration. Taking time out to review the situation with a calm, clear mind is, I think, time well spent.

I'll let you know how I get on. (Bet you can hardly contain your excitement!) 

Phil

A point Rupert makes in his book, so I must have read through it.

[Phil C]

Yes, got it out, as advised, thanks again, using the screwdriver and drift and hammer.   

Both forks now back on the bike.

I'll put the mudguard back on tomorrow. Then I'll have a look at the brake before refitting the wheel.

Saturday night now. Hot soak, then maybe a glass of something. Perhaps not what Saturday nights used to be, but still...


Phil