Topic: Broken bolt + broken extractor = broken heart.

[FunJimmy]

Ok, idea:  So, what is in the hole seems to be holding fairly well.  What if I filled the hole with something like alumiweld or some other permanent fix that would bond with the aluminum?  Whenever I need to change my fork oil I could just use the allen head bolt that connects the lower to the upper.  It would be 10x less of a PITA and probably just as functional.  Ideas?  Gripes?  Any reasons it wouldn't work?

JB Weld that sucker up and forget about it.
You can always remove the complete fork and tunr it upside down to drain.
Providing the cap has been removed obviously.
How often do you change fork oil anyway.

[DarcyCB400F]

 JB Weld that sucker up and forget about it.
You can always remove the complete fork and tunr it upside down to drain.
Providing the cap has been removed obviously.
How often do you change fork oil anyway.
[/quote]

+1 (or replace whole tube)

[MoMo]

+2 on the JB.  If it leaks add a bit more.  Dremel also has a cobalt grinding bit.  I used one to grind out a broken Easy Out(what a misnomer).  Eventually, the bolt and Easy Out were removed and I tapped to a larger size-that was a broken cam chain adjuster fix on a CB400f...Larry

[mjstone]

Lavis500-

I've recently changed out my front forks from my 500 for 550 forks.  I did this as part of converting to dual disk brakes.  I only needed to replace the right lower to do this, but I wanted to have the option of putting in cartridge emulators at a later time.  If you want my old forks you can have them for the cost of shipping.

MJ

[Lavis500]

mjstone - You are AWESOME.  PM sent.

[MoMo]

Where else but this forum could you get that kind of camaraderie?

[mjstone]

Your PM hasn't gone through yet.  If it doesn't you can always e-mail me.  My e-mail address is in my profile.  Be sure to reference the forks in the subject if you do.

MJ

[mjstone]

Got your e-mail.  I will get them packaged up and check on postage Monday.

MJ

[Lavis500]

Dave, I'm not thrilled at the idea of removing the whole lower and turning it out in order to drain it, but I spent a good bit of time yesterday beating this thing, and even my nice new punch set and my 3 lb BFH couldn't slam it through.  In fact, the tip of my punch started to suffer from some nasty mushrooming!   I considered drilling out from the aluminum surrounding the extractor, but I didn't want to make the hole too much bigger lest I compromise the integrity of the fork.

I feel confident about this fix, and I think it will last for a while.  ATM I just want to get her as close to riding before I leave the country as I can, and I'll finish the job when I come home.  Then she will be my riding project.  I'll spend years and years in an attempt to one day make her as beautiful as some of the more loved bikes on this forum.   

You're right, photolar.  It's true what they say:  You meet the nicest people on a Honda.  Or a Honda forum

[mongadillo]

For what its worth, although it sounds like you're well beyond this decision, I prefer timeserts to Helicoils.   
This is a tough story though, good luck, hope the JB holds.  I admit, I would be shopping for a new lower if I were in your boots. 

[mjstone]

The forks are in the mail. You should get them in about a week.  Cost me just over $20 to ship.  Don't send me any money, just make a donation to the Forum instead.

MJ

[DarcyCB400F]

+100%!! MJ
It's very nice what you have done to help out a fellow biker! Thanks!