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Help with forks: can these be saved?!

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Help with forks: can these be saved?!

PostAuthor: Vugar » Fri Aug 14, 2020 9:51 am

So while restoring the fork legs for my xv1100 i've noticed it had a lot of pitting after soaking it in apple cyder vinegar to remove heavy rust build up on it....maybe i left them in too much...Either way, can I save these fork sliders or are they far too damaged to be filled in with metal filler and sanded down etc? The only replacement forks I've been able to find are pretty much all from the US so would cost a fair amount to ship to UK. Any help is appreciated! Thanks
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Re: Can these be saved?!

PostAuthor: mark75 » Fri Aug 14, 2020 2:49 pm

it is hard to accurately assess from a photo, but they may still be serviceable although defaced.

you could try using JB-Weld (or such) as a Bondo-like body-filler then paint them. :con:

I mean all-you-can-do, is all-you-can-do, right?
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Re: Help with forks: can these be saved?!

PostAuthor: Vugar » Fri Aug 14, 2020 3:01 pm

My main worry would be regarding the safety of the forks. I have this hard metal filler but wanted to check if it even would be worth doing all that if the integrity of the sliders are compromised. I've read stuff like JB-weld etc works pretty well but haven't had much luck finding DIY results for pitted damage repair oddly enough

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Re: Help with forks: can these be saved?!

PostAuthor: mark75 » Fri Aug 14, 2020 3:15 pm

Vugar wrote:My main worry would be regarding the safety of the forks. I have this hard metal filler but wanted to check if it even would be worth doing all that if the integrity of the sliders are compromised. I've read stuff like JB-weld etc works pretty well but haven't had much luck finding DIY results for pitted damage repair oddly enough



I'm not an engineer, but I should think that (assuming 'normal' stress use / not-racing usage) they should be ok - if not leaking oil from any of the "pitting" now.

'86 is Gen-II. perhaps available from local bike-salvage?

the '86 p/n 42H-23136-01-00 was up-dated to p/n 3JK-23136-10-00 [to '99?]
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


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Re: Help with forks: can these be saved?!

PostAuthor: Jake » Fri Aug 14, 2020 3:59 pm

Aren’t they aluminum ?
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Re: Help with forks: can these be saved?!

PostAuthor: Vugar » Fri Aug 14, 2020 4:09 pm

I honestly have no idea! Would that make a difference? This is my first project so I'm not sure

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Re: Help with forks: can these be saved?!

PostAuthor: Jake » Fri Aug 14, 2020 4:26 pm

Aluminum doesn’t rust, so I cannot understand the rust. Aluminum is easily etched by acid, therefore the pitting.
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Re: Help with forks: can these be saved?!

PostAuthor: Jake » Fri Aug 14, 2020 4:28 pm

I have a few pieces of scrap aluminum, I’ll put some in a container with white vinegar to see what happens.
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Re: Help with forks: can these be saved?!

PostAuthor: Vugar » Fri Aug 14, 2020 4:30 pm

Of-course because aliminum doesn't contain any iron, very good point there. So my only guess is that I managed to f**k these up by leaving them in apple cider vinegar for too long to get cleaned up and it pitted the aliminum wihtout realising it's not actually steel. Any opinion as to if it is repairable or not?

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Re: Help with forks: can these be saved?!

PostAuthor: Jake » Fri Aug 14, 2020 5:33 pm

Vugar wrote:Any opinion as to if it is repairable or not?


The only thing I could suggest is the same as mark75.

I just dropped a piece of aluminum in white vinegar, I’ll check it over the next couple of days. How long did you leave it in the cider ?
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Re: Help with forks: can these be saved?!

PostAuthor: faffi » Fri Aug 14, 2020 6:05 pm

I went from this
Image
Image

to this with about an hours work and some paint
Image
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Re: Help with forks: can these be saved?!

PostAuthor: Vugar » Fri Aug 14, 2020 7:12 pm

Jake wrote:
Vugar wrote:Any opinion as to if it is repairable or not?


The only thing I could suggest is the same as mark75.

I just dropped a piece of aluminum in white vinegar, I’ll check it over the next couple of days. How long did you leave it in the cider ?



I think just about 4-5 days

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Re: Help with forks: can these be saved?!

PostAuthor: mark75 » Sat Aug 15, 2020 6:29 pm

Vugar wrote:Of-course because aliminum doesn't contain any iron, very good point there. So my only guess is that I managed to f**k these up by leaving them in apple cider vinegar for too long to get cleaned up and it pitted the aliminum wihtout realising it's not actually steel. Any opinion as to if it is repairable or not?



look in the 'bore'. if it's still smooth - with no pits like outside - the structural integrity is probly still pretty-much intact. the pitting is only on the 'surface'.

you could then, with little concern, fill and paint it like faffi did (hopefully yours will look as good as his) :naughty:

I might even consider using some of that "instant chrome" spray - the videos make it look real easy & almost like the real thing. >>> https://www.carbibles.com/best-chrome-spray-paint/
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


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Re: Help with forks: can these be saved?!

PostAuthor: Flyingdog » Sun Aug 16, 2020 2:33 am

As everyone, above, have said..the sliders look fine (structurally). Make'm look purdy is all that's needed. I just wanted to suggest, look'n at your final pic, the very inside "contact surface" for the socket bolt/washer (that locks the tapered spindle to compression tube) looks to be somewhat pitted also. Can't tell for sure from the pic, since it's way in the recess. May save few headaches/leaks, if something like smear of Yamalube sealant (or some non-hardening equivalent) is applied to that copper washer.
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Re: Help with forks: can these be saved?!

PostAuthor: Jake » Fri Aug 28, 2020 4:15 pm

It’s been 14 days since I put some aluminum in vinegar, and as I suspected the vinegar ecthed the metal. Now there are different grades of aluminum and add to that, your forks may have had some road salt on them that may have contributed to the pitting.

7DF41A50-D124-4803-849B-EDD3C9BAF1D9.jpeg

6059BDBE-4E5A-4D7C-8B1A-35992D711807.jpeg


I neglected to take a before photo of this next piece. You can see where it was submerged and the pitting that occurred.

509122C5-5E08-43E0-935D-4157D30A35A4.jpeg
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Re: Help with forks: can these be saved?!

PostAuthor: Vugar » Sat Sep 12, 2020 7:07 am

Apologies for the late reply guys. Thank you for confirming the suspicions! Now I have bad news and good news. Bad news is that as one of the guys mentioned about the potential of pitting reaching the inside bore: after soaking them in rust removal solution and cleaning I have spotted that unfortunately the inside is slightly pitted as well, so simple filler on the outside won't work. Simply put, they are busted

Good news is I managed to source a pair of forks on Gumtree of a chap that was breaking his xv1100 for parts for a very respectful price

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Re: Help with forks: can these be saved?!

PostAuthor: mark75 » Sat Sep 12, 2020 6:01 pm

that may be the easiest/most direct route to get some 'slick-new-legs'.
you're the one with the "eyes-on" it all (+ expending the cash)

however, front shocks are unlike hydraulic-cylinders (that require all surfaces be smooth to work properly).
as I recall the sliders role is mostly supportive and to keep the damping stuff inside. (fork seal for fluid containment not pressure)
"Over the Mountains of the Moon,
Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


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The views, opinions, and experiences expressed in this post are mine and may not necessarily represent views and opinions of other VTF members, so feel free to agree, disagree, or ignore them.
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Re: Help with forks: can these be saved?!

PostAuthor: Hellgate » Sat Sep 12, 2020 8:18 pm

Personally, I'd look for new sliders/forks. Those are toast.

I left my RZ350 calipers in pure Simple Green for several days. The paint pealed off a the aluminum pitted too. I trashed them and found a new pair. If the outside is that bad so is the inside.
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