Topic: so my forks have a bunch of surface rust

[Ayrity]

So the previous owner removed the turn signal ears off the forks, and I like the way it looks, only problem is the area where the ears covered is not covered in surface rust, I'm sure it isnt a problem as far as strength of the forks, because I assume they would be rusted under there even if the chrome ears were over the area, but I want to cover them again without putting on ears, and without sanding the hell out of them. I was thinking maybe using those black rubber fork covers that usually go lower down and cutting a slit for the headlight bracket? any other ideas for me? Some kind of custom chrome/black cover like a black plastic piece I can slide over it? Also sorry I don't have an exact picture of the area, but you can see it in the two pictures I put up, let me know if you guys need a close up.

[domer]

plumbing section of hardware store, get a straight chrome section of drain pipe... about the same diameter as your tubes.cut to length between trees, cut a slit length wise. slide on to fork tubes, use headlight ears to clamp down. point the slit at an angle you cant see and voila... $5 fix! this is obviously the short of it... i can detail more if you need it!

[Gordon]

Regardless of what you do to cover up the ugly sections you should still do what you can to remove the rust and treat the metal so it doesn't come back.  If it continues to rust it will eventually weaken the forks enough to where it could cause a serious problem. 

[Ayrity]

will probably do both of your suggestions, heading to lowes now thanks!

[Ayrity]

so i got some 8 inch chrome tubes, they look like the perfect length, but they seem like really solid pipes and i dont think i can cut and bend them around the fork, so how hard is it to take off the top fork bolt and the brackets and slide it down over the pipe? it looks like it will be a really snug fit, like if i sanded and greased it up I could get it on with a rubber hammer. I also wonder if it is safe to put the steering brackets over this chrome pipe, it will be a really good fit, not loose or anything so I dont think there would be a problem, but you guys know better than I do...

Edit: also, is it ok to just take off the steering bars and top fork bolts and loosen the black steering clamps that attach the forks together to push these chrome pipes on? or do I HAVE to take the whole fork off?

[domer]

ya you gotta slide the fork tubes out...cut a slit in the pipe so it can clamp on to fork tube via the headlight bracket, little bit of work, but works like a charm

[Ayrity]

ya ok I figured, thanks. my other question is do I have to take the top seal bolt off to take the forks out? the manual I have is kinda vague. Also, I'm having new tires put on tomorrow, do you think it would be a good time to maybe ask the shop to help me since the tire will be off the bike anyway? and thats half of removing the forks right?

[domer]

if the guy in the shop is cool and bored.... sure. that or just prop your bike up on a milk crate and bring the wheels in your self.
basically remove wheel, remove caliper (carefully hang from something), remove fender, loosen the 4 nuts on the triple trees, coax fork tubes off... coaxing might require a rubber mallet, or hammer wraped in a towel. oh dont forget to remove the headlight... do a search on front wheel alignment before you begin, its easy to do and easy to over look...

[Ayrity]

great! thanks domer! ill show you guys some pictures if you want, and if I get it done anytime soon.

[Ayrity]

ok, so I tried to get the chrome covers on the bike, and I can not for the life of me figure out how to either get the cover past the fork clamps or to get them under the fork clamps, either would be fine, as long as the chrome goes right up against the clamps. I can slide the forks out just fine (and by just fine, I mean with a lot of unsticking) but i cant seem to get the clamps to open up enough to accept the chrome covers to go under them. Any other ideas?

[lone*X]

If I understand what you are wanting to do, the area to be covered is generally between the trees, correct?  If so cut the chrome plumbing tubes to a length that is a close fit between the trees, hold the new cover in place between the trees and slide the fork tube back up thru the lower tree, the cover, then the top tree.  No need to open the trees up so far as to get the covers thru them.  You will need to figure out how you are going to mount the headlight.

[Ayrity]

duh, that makes sense. I was just trying to find a way to not have to remove the forks, guess I have a weekend project now. thanks!

[HawaiiMike]

This is a great idea, Domer do you have pics of the finished product?

[faux fiddy]

Be careful tightening the pinch bolts on the top triples. I have a pair that are shot. I think there is a washer that in it's absence it is really easy to break the pinch collar.

Maybe someone will chime in, I haven't had mine apart, but I do have a set of upper triples that have been broken, and I think this is a common problem if you overtighten or do not have the washer in place. ANyone got info?

http://forums.sohc4.net/index.php?topic=53960.0

[H2Eric]

Those little washers are still available from Honda as far as I know. I got a pair about a year ago.

Cheers
Eric

[domer]

This is a great idea, Domer do you have pics of the finished product?

i personally havent done it yet, although it is on the list since my stock ears are all kinds of f'd up and the forks underneath are pretty bad. i wish i could take credit for this, but i found it over on DTT. it actually looks pretty good when done right. ill try and dig up a pic, as a couple people over there have gone this route...

[cafe550]

bringing this back up again does anyone have pics of this done

[shizzomynizzo]

Save yourself the time and just paint them!

Or do a conversion to modern forks and make yourself even happier

[domer]

only problem with paint is your gonna have to paint them while they are on the bike, or your gonna screw it up sliding them through the trees... a modern front end would be great, but that requires the lovely yet elusive green paper my wife hides so well! so here are some pics of the $10 idea stolen from another forum, cheesy, yes. but hey it sure as hell looks better than rusty tubes...

[cafe550]

only problem with paint is your gonna have to paint them while they are on the bike, or your gonna screw it up sliding them through the trees... a modern front end would be great, but that requires the lovely yet elusive green paper my wife hides so well! so here are some pics of the $10 idea stolen from another forum, cheesy, yes. but hey it sure as hell looks better than rusty tubes...

that don't look to bad thanks for the pics

[mrbreeze]

I swapped over about 3 years ago to the newer style forks (without the gaiters) and found me some tubes off a Hondamatic on Ebay. I do like this idea about the chrome drain pipe to cover the tubes if you reuse them. I might try that on one of my project bikes. As mentioned......you do have to have those washers in your triple trees. If you find them missing.....you may wanna check for cracks.

[Duanob]

Save yourself the time and just paint them!

Or do a conversion to modern forks and make yourself even happier

Ditto! Mine were rusted so I took some fine emery cloth to sand the rust and painted with enamel just where the unploshed starts up to the top. Since I put the gators and chrome ears back on you can't even see it but it's protected now.

And get yourself some dust boots to keep water out of the lower fork seals. My guess is if you didn't have dust boots or gators on your bike for a while your forks or full of water/oil. There is a reason for boots or gators. There are FAQs on rebuilding forks. I did mine it's easy and well worth it.

Scroll down to the bottom of this website there is a slide show that shows a good pic of your situation. upper fork tube sanded clean and left that way.

[cafe550]

Save yourself the time and just paint them!

Or do a conversion to modern forks and make yourself even happier

Ditto! Mine were rusted so I took some fine emery cloth to sand the rust and painted with enamel just where the unploshed starts up to the top. Since I put the gators and chrome ears back on you can't even see it but it's protected now.

And get yourself some dust boots to keep water out of the lower fork seals. My guess is if you didn't have dust boots or gators on your bike for a while your forks or full of water/oil. There is a reason for boots or gators. There are FAQs on rebuilding forks. I did mine it's easy and well worth it.

Scroll down to the bottom of this website there is a slide show that shows a good pic of your situation. upper fork tube sanded clean and left that way.

i did have the fork boots over the seals but this it what i found when i tore them down they were full of water and grime im getting rid of the boots and ordered a set of new seals and dust seals