Oh crap, I screwed up!

[kamal]

Got my forks apart and cleaned. Decided to replace the bushings and seals before installing the AK-20 cartridges.

Got ahead of myself and put the new outer bushing in the leg before putting the tube in - duh!!

What is the best way to remove it? I know I am going to wreck it and will have to order another, so should I just weaken it with a dremel?

Now for several beers.

Thanks.

Al

 

[ahchiu]

Try a 90 deg pick to hook the bottom edge and work around and it pull out. I would not use a Dremell it will leave metal crap in your forks and you will really have to make sure it's cleaned out well.

 

[escapefjrtist]

How hard was the bushing to drive in?

Try ahchiu's idea first adding a little heat to the OD of fork leg. Might get the leg to expand enough to loosen the fit and remove. If that doesn't work then...regardless of metal debris, you'll need to relieve the fit to remove it easily.

Good luck, I'm sure they'll be other ideas coming soon!

--G

 

[ahchiu]

If you must cut the bushings stuff a paper towel in the tube to catch the metal shavings.

 

[kamal]

How hard was the bushing to drive in?
Try ahchiu's idea first adding a little heat to the OD of fork leg. Might get the leg to expand enough to loosen the fit and remove. If that doesn't work then...regardless of metal debris, you'll need to relieve the fit to remove it easily.

Good luck, I'm sure they'll be other ideas coming soon!

--G

It was quite tight, the old ones almost fell out!

I think I'll end up stuffing towel down and cutting it. I'll blame Marcus if I mess up

.

Thanks guys!

Al

 

[Surly]

Hi Al,

Hope it goes well. Could an engineering shop offer a better solution?

Best regards

Steve

 

[SeattleTy]

Maybe give Traxxion a call, they might have a solution, good luck and hang in there, it will work out

 

[HYCLE]

What you need is a tool like this. https://www.mxsouth.com/pitposse/pit-posse-chassis-related-tools-blind-bearing-and-bushing-remover.htm

Check with a transmission shop, they may remove it for a small fee.

 

[Bustanut joker]

Al, come to tech day Vl.. You can assist me an Andy, and as yer from Kanada, you'll feel right at home with the three regulars.

 

[odot]

Maybe heat the outside of the fork up a bit.

 

[kamal]

Al, come to tech day Vl.. You can assist me an Andy, and as yer from Kanada, you'll feel right at home with the three regulars.

Thanks Bust. Do I get this invite because I've announced to the world that I'm a screw-up?

Al

 

[kamal]

Hi Al,Hope it goes well. Could an engineering shop offer a better solution?

Best regards

Steve

Might end up going that route Steve. I'll try the Dremel first, a series of small cuts should weaken it.

Still want me to come over and do your suspension?

I thought not!

Cheers.

Al

 

[ahchiu]

Al,

I talked to KFG racing and they suggest you take the plastic fork guard off and heat up the fork tube short of burning the coating and use two 90 deg feeler picks or thin flat head screw driver and hook under the bushing and pull/pop out, they said to cut as a last resort and be careful not to nick the inner tube.

 

[gixxerjasen]

Try making something before cutting I'd think. Flat piece of metal over the end with two holes drilled into it. two bolts with the ends ground down with the dremel to be kinda flat and then bent or something to fit under the edges. Before doing all that, put nuts on the bolts and feed them through the holes, then start doing the grinding and bending. Then turn the nuts to pull the bolts back with them hooked under the edge.

I dunno, something I might try with the spare crap hanging out in my garage. Cutting them seems like a bad option. Probably wouldn't work though as I'd screw it all up somehow. I love these threads because this time it wasn't me.

 

[odot]

Maybe heat the outside of the fork up a bit.

Um, what I said.......lol

 

[kamal]

Thanks for all the help guys.

My millwright neighbor, who works mainly on hydraulics, had a small, expanding, two-legged attachment for a slide-hammer that popped it out OK. Still managed to scratch up the bushing though, new one on order.

A learning experience for me, especially now I'm on the downhill side of sixty and back to thinking with the 'big head', which was dormant for a number of years

.

Back to the moped project.

Al

 

[Iris]

Glad you remedied it.

I would have also suggested a "Blind Bearing And Bushing Remover" as someone stated above.

 

[kamal]

Glad you remedied it. I would have also suggested a "Blind Bearing And Bushing Remover" as someone stated above.

Thanks Iris.

I should see what Princess Auto (the mechanic's dollar store) has.

Al

 

[Surly]

Hi Al,Hope it goes well. Could an engineering shop offer a better solution?

Best regards

Steve

Might end up going that route Steve. I'll try the Dremel first, a series of small cuts should weaken it.

Still want me to come over and do your suspension?

I thought not!

Cheers.

Al

Now that you have practised on your bike you are most welcome back here, I will vouch for you.

Glad you found a solution that avoided cutting tools.

Best regards

Surly