Should I bend my lower clamps?

[indywar360]

Just disassembled, cleaned, replaced seals, added Progressives, and reassembled a used replacement pair of forks.

I suspect my lower triple clamp is bent but the replacement pair I got is rusted (thx a lot Jarrett)  so I'd rather use the one I already have.

If it *is* bent as I suspect, could I (in theory) use my old fork tubes to bend the lower triple back into shape? I've seen no mention of this but it seems doable. I am going to go for it tomorrow... wish me luck.

Any advice I find on here by tomorrow would be highly appreciated.

Kyle

[The Buddha]

Rust is better than bent, scrub it and paint it. Dont worry about looking rough, it looks like sheite when new. That sheite is cast iron. Will fall apart if you fook around with it.
Cool.
Srinath.

[rob1bike]

If it is cast iron you don't want to bend it

[Chuck]

Yeah, use a rust remover pad drill bit thingy, and/or some rust remover gel (phosphoric acid), then prime it and paint it.  It will look like sunshine.  I had to do that to the entire frame of my FZR because the previous owner thought it would be cool to polish it. 

[Wondertwin]

Rust is better than bent, scrub it and paint it. Dont worry about looking rough, it looks like sheite when new. That sheite is cast iron. Will fall apart if you fook around with it.

Big plus one on that!

[dgyver]

Trying to bend the lower clamp is not going to be easy. You can try to use an old fork tube but it will probably bend before the clamp. Better have access to a hydraulic press. The hard part is going to get both holes parallel, especially since you will have to over bend it so it will spring back to the correct position.

[coll0412]

Yeah just repaint the old one, having to bend the old == pain in the arse

Think how much force it took to bend it, you will not be able to due it by hand.

[Chuck]

having to bend the old == pain in the arse

1. pain in the arse
2. hard (nigh impossible) to get right
3. dangerous (doing it, as well as using it afterward)

[indywar360]

Replacement forks went in fairly easily, as did the fender brace, but then when I put the axle thru the forks it was off center, causing the axle to bind at the second hole. Damn. Guess I will have to replace the clamps too... or just force the damn thing.

Question:

My old fork tubes had a hex nut-style cap. The replacements ('89 type) have a square socket. I switched the caps out since I like the nut style ones better, but they seem to be shorter or something... it fits, but the rubber ring just goes inside rather than pinching between the cap and tube.

Think this is ok?

Also, my "new" 89 outer tubes don't have the plastic shield that protects the dust and oil seals, or the mounts for side reflectors. Are there readily available aftermarket seal guards and how would you suggest mounting replacement reflectors?

Thanks   
Kyle

[Jared]

Actually it's spelled Jared.... and was the thank you cynical?  You're talking about the little bit of surface rust under the lower side of the bottom clamp???

Ther're off an 89...they're not aluminum....they were going to have rust on them.

When you say your axle bolt binds up...which way is it binding up in your original clamps?

Is it the fork lowers are off vertically?  Ie they dont stick through the clamps at the top the same amount?- Check to see if they shifted or anything after you put them in and tighened the clamps. Or is it horizontally that they don't line up ( meaning they forks are toed in or out)?.

Loosen the clamps and fork brace  up....make sure the forks are even in your top clamps...tighten the top ones up a little so that they stay where they are.  if you have to wiggle it in it's normal...the fork lowers spin on the tubes..if you have the lower brace all bolted in you may have the fork lowers out of alignment-  the lower braces are slotted and  have play in them  ( enough to make the axle bolt bind up).

[indywar360]

Actually it's spelled Jared.... and was the thank you cynical?  You're talking about the little bit of surface rust under the lower side of the bottom clamp???

Ther're off an 89...they're not aluminum....they were going to have rust on them.

When you say your axle bolt binds up...which way is it binding up in your original clamps?

Is it the fork lowers are off vertically?  Ie they dont stick through the clamps at the top the same amount?- Check to see if they shifted or anything after you put them in and tighened the clamps. Or is it horizontally that they don't line up ( meaning they forks are toed in or out)?.

Loosen the clamps and fork brace  up....make sure the forks are even in your top clamps...tighten the top ones up a little so that they stay where they are.  if you have to wiggle it in it's normal...the fork lowers spin on the tubes..if you have the lower brace all bolted in you may have the fork lowers out of alignment-  the lower braces are slotted and  have play in them  ( enough to make the axle bolt bind up).

I was being sarcastic about the rust but not really serious. And the lowers are off horizontally, i.e. the axle bolt rubs the rearward side of the lefthand lower bolt hole.

I'm going to bicycle my front tire to the shop right now to have them do the bearings (frigging impossible without some kind of tool I dont have), then backpack my gear to the parking garage and fix that mother before I have to go to work today.

Thanks Jared and ... wait... there is a Jarrett on here too. I saw Jarrett and I was like, whoops, I been mispelling Jareds name this whole time.   
Kyle

[indywar360]

Went on like a dream... Incredibly, my lower clamps were straight, in spite of both forks being bent. I loosened the fender brace as you suggested Jared, it freed up the lowers and the axle bolt slid through nicely.

Can't wait to go for a ride on my newly straight forks... hopefully I remembered to tighten everything correctly.

Thanks Jared, and everyone else who gave input.