Topic: Goldwing front end swap -- problems solved; now includes a how-to!

[Terry in Australia]

Any good machine shop can cut and internally rethread your forks Noel, I use Honda 35mm XL250/350 fork tubes on my CB750's and have them cut and re-threaded by my local shop, cost last time (last year) was $80.00 for the pair.

While you're there, ask 'em about making you a new top triple clamp to replace your JB weld/alloy plate attempt, once again it shouldn't be too expensive, but may well save your life! Cheers, Terry.

[Noel]

Well, I may try having the fork tube tops chopped and rethreaded. I'm still concerned that that portion is more complicated than a simple rethread, but I put some effort into finding spotless tubes to begin with and it would be a shame to ditch them for something new -- and expensive -- from Frank.

FWIW, WingStuff.com -- brick and mortar headquarters less than a mile from me, which is nice -- offers fork braces for this model front end. A bit pricey at $140, but handling really is a bit spooky without anyting holding the sliders together.

I'm not too concerned about the top clamp. Yeah, it's got holes, but it doesn't appear to me that there's any real structural issue with it. You kind of have to see the before and after in person to see what's going on. The covers I made are almost entirely for cosmetics. I have the tiniest bit of concern about crack propagation from the tightening/loosening slits, but think even the small amount of reinforcement from my covers will prevent that. The main issue is that I didn't even notice those slits until after I'd completed the first cut. If you don't watch for them while planning your cuts you could easily run into them, which would simply destroy the piece.

[DME]

Well, I may try having the fork tube tops chopped and rethreaded. I'm still concerned that that portion is more complicated than a simple rethread, but I put some effort into finding spotless tubes to begin with and it would be a shame to ditch them for something new -- and expensive -- from Frank.

Yes, it´s a little more complicated than a simple rethread. But i can be done!

On a trip to Aussie back in -98 I found a pair of NOS stanchions that were an inch taller than stock. They might be KZ-stancions. Bought them for 2$ (!) and brought them home to Sweden.

Anyway, a friend of mine cut an inch of the top end off and cut a new thread in the lathe.
That´s pretty much the only way you can do it.
Finding the correct tappet for those fine threads is near impossible, but a good lathe-operator will be able to cut it for you.
Mind you, don´t give the job to someone who "says" he´s good, find one who really is! You only get one chance

Cheers
Daniel