how to fix punctured fork lowers?

Discussion in 'Downhill & Freeride' started by Kram, Dec 23, 2007.

  1. Kram

    Kram Chimp

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    Hi - searched a bit - found nothing.
    Trying to revive a friends old boxxer which has a small hole half way down the leg (not the stanchion).
    Is there any decent way to plug it, and for it to be strong enough to last. Doesnt really need to be tidy. just do the job.
    cheers
     

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  2. Udi

    Udi RM Chief Ornithologist: “I Brake for Birds”

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    I've seen them carbon wrapped before which works a treat, but you obviously need somewhere a little specialized to do something like that.

    I'm sure other wraps/patch ups are possible too though, probably cheaper ones if you don't care about looks.
     
  3. nmn25

    nmn25 Monkey

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    jb weld. If its strong enough for boilers and engine casings, its strong enough for fork lowers.....
     
  4. Kram

    Kram Chimp

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    thanks. Yeah i thought i had read about using jb weld somewhere before. Found a couple of threads on repairing scratched stanchions with it, but wasn't sure about using it on the punctured legs which will have the pressure buildup from within.
     
  5. danielsapp414

    danielsapp414 Monkey

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    buy new ones...it'll cost a couple hundred depending where you get them. you can have any bike shop order them through BTI.
     
  6. jonKranked

    jonKranked Press Button, Receive Stupid

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    i dunno if it would be effective... but you could try wrapping it in fiberglass then hardening it with the epoxy enamel stuff...


    i'd go with jb weld though
     
  7. dropmachine

    dropmachine Turbo Monkey

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  8. Horror Business

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    Try JB Weld, but keep your fingers crossed. If that fails, just buy new lowers. There always seem to be old boxxers on ebay for cheap $$$, he can buy one, use the lowers and keep the rest for spare parts.
     
  9. EVRAC

    EVRAC Monkey

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    jb weld
     
  10. FrontRangeDH

    FrontRangeDH Monkey

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    Cut up a beer or soda can and JB weld it into place so it gives more surface area for the bond to adhere to make it stronger or just buy an old boxxer for parts off ebay, they are pretty cheap
     
  11. dcamp29

    dcamp29 Monkey

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    i did it- held oil just fine but the lowers dented the bushings which caused other problems
     
  12. intensem1

    intensem1 Monkey

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    Well i tried JB weld on my cracked lowers several times and it just kept leaking out, but i didnt try using a can.

    I have a 2005 Boxxer Race for sale 50.00-Cracked Lowers
     
  13. motomike

    motomike Turbo Monkey

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    that is American
     
  14. jonny dh

    jonny dh Monkey

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    as the red green show would put it {use duck tape}
     
  15. DirtyMike

    DirtyMike Turbo Fluffer

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    Easy temp fix, Take the lowers off, clean them up, install pipe plug. Might need to drill with a small dril then tap it to fit the pipe plug, and of coarse Tourque it to specs, youll need to find the specs for the plug your using, maybe a little red loctite on it to help. Other than that, just order a new set of lowers, there not that costly
     
  16. ChrisKring

    ChrisKring Turbo Monkey

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    We repaired one with JB weld a couple of years ago. It worked good enough until the kid could save up some cash for a new fork. The problem was that the lower was also dented which caused interference with the stantion. We were able to reduce that by pounding a wood dowell down into the lower. Still rubbed though and blew oil out the seals once the stantion got scratched from the intereference.
     
  17. bizutch

    bizutch Delicate CUSTOM flower

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    Ridemonkey saves the day with the searcg tool. will post pics if successful.
     
  18. TrumbullHucker

    TrumbullHucker trumbullruxer

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    my buddy punctured his 40 lowers

    jb weld did it perfectly.. just make sure you LIGHTLY wire wheel the paint and shiz away, and apply, (make sure you have some kind of radius "tool" on the inside so it does not penetrate too deep )

    unfortunately the day he rode, he then cracked his arch blowing a berm.... the jb weld held up perfectly though lol

    (p.s anyone have 40 lowers for sale haha)
     
  19. bizutch

    bizutch Delicate CUSTOM flower

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    I guess finding some 06-09 lowers would be easier. Anyone?
     
  20. Sandwich

    Sandwich Pig my fish!
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    I wondered why everybody was being so helpful...
     
  21. blindboxx2334

    blindboxx2334 Turbo Monkey

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    i will oblige sandwich

    'duck tape and zip ties is all you need'
     
  22. WestCoastHucker

    WestCoastHucker Turbo Monkey

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    because that's how it was around here 7 years ago...
     
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  23. bizutch

    bizutch Delicate CUSTOM flower

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    Bought my JB Weld today. Countdown to rigging begins.
     
  24. metalMTB

    metalMTB Monkey

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    if i were you i'd take the lowers off ( couldn't hurt to change the oil anyways) and feel around the inside of the puncture. chances are, it's not going to be smooth so I would sand it down with super fine sandpapers and flush out the dust out with some fresh oil. that way you can reduce any stiction that might occur without sanding.
     
  25. Jm_

    Jm_ Turbo Monkey

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    I'd just put a rad sticker on it.
     
  26. metalMTB

    metalMTB Monkey

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    or gorilla tape if you are extremely lazy.
     
  27. bizutch

    bizutch Delicate CUSTOM flower

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    So I busted out the JB Weld and a section of SunDrop can. The "gouge" was more of a scrape, so it looks like it worked pretty well. Taped up with Duck brand duct tape, powder blue borrowed from the daughter (b/c they have about 8 rolls each with those flippin patterns) :) .

    Rode Beech Mtn Bike Park pretty darned hard Saturday and looks like it will hold up nicely. Long term report will follow...long term?
     
  28. bizutch

    bizutch Delicate CUSTOM flower

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    Long term report. It's still rocking.