JOG:

The Savage forks are a winter project.....I am currently working to get my yard reseeded, firewood cut and stacked, etc.

The last two days I have been shoveling dirt, raking, seeding and spreading straw in shorts and a T shirt......this nice weather is not going to last.

Dave

It rained last night, and was 40 degrees this morning....so I hid in the garage for a while and got the broken fork legs apart.

First I had to get the broken spring out - I used a set of vice grips and grabbed the end of the spring and twisted them out.....not too tough.

Then I took the dust caps off....easy.

Then I used the holder I made for the damping rod and took the allen screw out of the bottom.......mostly easy but the screw were very tight.

Then I took the spring keeper off the top of the seal, and then used the fork tube like a slide hammer and the seals and guts came out of the lower fork tubes.....pretty easy.

The hardest part was when the damping rods would not come out of the bent tubes.  I had to put the tubes in my lathe and cut the bent part off, then deburr the tube.  Make sure the damping rod is at the bottom so you don't cut on it while cutting the tube.  You could cut them off with an abrasive wheel.....they may be a bit hard for a hacksaw.  This was not that hard when you have a lathe!  I think the entire process took about half an hour.

Now that I have the lowers apart I am going to strip the clear coat and get the scratches out and polish them.....the add a clear coat.  This process is definitely something that will wait until winter arrives.

The forks I got where from some unknown eBay bike.  It was a 2006 with only 1,700 miles on it.

It is really quite scary how many of the bent forks are from "low mileage" bikes.....I suspect they are new riders who have traveled faster than their ability to slow down and/or stop when needed.