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16 Dec 2020
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My Right (Fork) leg is broken.... 1 month 4 days ago #8283

  • twistandgo
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uh oh. As I continue my attempts to get Gilly looking lovely I have just found a possible major problem.
My right fork leg has lost a chunk of metal and is leaking oil. It's in a strange non-stressed part of the fork, so I have no idea how it could have happened. Perhaps a prang in the past, or a ham-fisted attempt at fitting new fork seals?
Anyway - I've had a quick look on eBay and there's nothing there apart from some expensive old forks in Australia. Before resorting to JBWeld or something like that I wondered if it's possible that someone on here might know of some new or secondhand ones lying in a shed...
Failing that - does anyone know if the same forks were used on other bikes of that era?

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My Right (Fork) leg is broken.... 1 month 3 days ago #8290

  • KAB
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In this case I would probably do like this. Make a good fitting sleeve out of stainless steel (needs to be removed after the process) that fits where the seal would normally be. Make sure everything is spotlessly clean and with a map-gas torch heat up and apply Durafix solder eg www.oxfordweldingsuppliesltd.co.uk/gas-e...uminium-welding-rods to build up to the required profile. Then finish with flap disc/file etc. Use a dremel tool to form the groove for the retaining clip. Magic solder in my eyes!
Cheers
Keith
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My Right (Fork) leg is broken.... 1 month 1 day ago #8291

  • Kano Nordi
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If I had the problem I may even be tempted to leave the sleeve in place as a little reinforcement.
John

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My Right (Fork) leg is broken.... 2 days 11 hours ago #8314

  • twistandgo
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An update...thanks for your ideas - I opted for getting the leg welded up, but as my welding skills and experience are non-existent I popped over to a local welding business down here in Kent and they filled the area in with alloy weld (along with a few other nicks and chips) for the princely sum of £40. Bargain.
I attacked the resulting metal blobs with the mighty dremel (other rotary tools are available) and did what I think was a passable job. I was going to take a photo to impress you all with, but decided to put the leg back together again to make sure that everything fitted as it should - and realised once I'd completed the work that it DID all fit, and I wasn't going to pull it apart again.
Anyway - the proof of the pudding is in the riding, so once I get my newly-chromed exhaust header back from the chromers and put the bike back together I'll take it for a test run. If it leaks then I guess I didn't do the passable job I thought I had...and will need to break out some gasket sealant or something similar to seal it all up.
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My Right (Fork) leg is broken.... 2 days 4 hours ago #8316

  • KAB
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Cheap enough at that! Hope it does the business.

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