Been thinking- fork swap

Well thats interesting. So your saying a lower GG 48mm Sachs clamp is basically a bored lower GG 45mm Zoke clamp? So then the new '12 48mm Zoke clamps are probably the same. I don't know what to think now.:confused: I might still be worried about machining stresses being set up, have to talk to someone more knowledgeable than me in this area.
 
Aluminum is easy to machine. Stress in the material itself should not be an issue. The best way would be to have a shim in the clamping gap with the screws done up to the correct torque, then machine the bores. Fixturing the fork crown securely will be the most work.

Use a telescoping gauge to measure the bore in several directions. Adjust the clamps screws so the bore is round. Now you can measure the gap using feeler gauges to know what shim thickness is correct.
 
Smart people rock. If not for you, us dumb ones would be licking the windows all day.

I keep playing all this stuff out in my head.

Current thought, LMAO:
machine my lowers to correct spec for showa.
Get bearings and seals for GG wheel to fit Honda axle.
Get Nissin brake mount for Honda/showa or built custom plate for proper alignment of pad to disc. Might just weld on a tab and thread it.??

I will need to pull my forks and measure the billet clamp thickness to ensure this is even viable. I still have options for building a lower or customizing the honda's to fit.
 
I was given a brand new pair of 48mm kyb cart forks.
I was thinking about picking up a yz tripple clamp and having a machinest make me a new stem to fit the GG.
Could probably do it for about 3 to 4 hundred dollars.
Still playing with the idea.
 
Stayed tuned. Showa's will be here next week.

I will give you an update once I have them in my hands and all precise measurements are taken and we have the instructions drafted for the machine shop.

Bore Lower triple to showa dimensions
Bore fork axle clamps to GG axle dimensions
Machine spacers. May not be needed.
Machine brake bracket to fit 260mm brake.

DONE. If all goes well. : ) I will rebuild the forks and install new upper springs from the get go and set oil height etc for off road. Stoked to see if this all works as well my little window licking brain can imagine.
 
Brent,

While its more compliated, I like the idea of using the GG wheel, as I have spares. What about just machining a custom axel rather than boring the fork axel clamps?
 
I am not sure how you would machine a customer axle to fit the 25mm gg bearing vs the 20mm showa fork. I realize you can step the axle but I am not sure how you ensure everything is tightened correctly. I like the idea but then again you will have 25mm solid axle that is going to have a bit of weight to it.

I am not yet convinced it is more or less complicated. I have a couple of options:

1. BUY a Honda wheel....not cheap. $200 with shipping etc. Does solve the brake mounting issue tho. Have to buy a honda brake caliper $30. If I want the wheel to match the back I have get a black rim. $100

2. Get bearings and seals to fit the gg wheel and the honda axle. The correct dimension is difficult to find and right now the only ones we have found are in Europe.

If I can use the GG wheel, bore the fork, then all I have to do is ensure the spacers are aligned or make the correct ones. The brake mount is the most complicated issue to be solved.

The question I have yet to answer is, will the gg nissin caliper fit the honda brake bracket? Since I have never messed around with the mounting brackets I have no clue what to expect. Learning.
 
BrentMartell said:
I am not sure how you would machine a customer axle to fit the 25mm gg bearing vs the 20mm showa fork. I realize you can step the axle but I am not sure how you ensure everything is tightened correctly. I like the idea but then again you will have 25mm solid axle that is going to have a bit of weight to it.

I am not yet convinced it is more or less complicated. I have a couple of options:

1. BUY a Honda wheel....not cheap. $200 with shipping etc. Does solve the brake mounting issue tho. Have to buy a honda brake caliper $30. If I want the wheel to match the back I have get a black rim. $100

2. Get bearings and seals to fit the gg wheel and the honda axle. The correct dimension is difficult to find and right now the only ones we have found are in Europe.

If I can use the GG wheel, bore the fork, then all I have to do is ensure the spacers are aligned or make the correct ones. The brake mount is the most complicated issue to be solved.

The question I have yet to answer is, will the gg nissin caliper fit the honda brake bracket? Since I have never messed around with the mounting brackets I have no clue what to expect. Learning.
Click to expand...

If you are using a smaller axle on larger bearings, you can make stepped spacers to size down the bearing opening. I have made and used them with great success. The spacer on the left is a stepped bearing that adapts a smaller axle to a larger bearing. Same axle diameter on both spacers.
IMAG0385.jpg
 
Doesn't have to be solid, just leave a couple mm where it steps from 25 to 20 mm. It only needs to be 25mm across the bearing races of both sides, then custom spacers do the rest. Go to a Honda dealer with a caliper, probably the same.
 
FYI and BTW....the KTM rear wheel spacers are very close to the right fit. They are 20mm inside and 25mm to the small step. Fit the gasgas inside bearing diameter perfectly. The big step up needs to be machined down to fit the gg seal.

I have 4 spacers that I might just have the machinest turn down etc if boring the fork is not going to work.

IMO- boring the fork is the easiest, but we will see once I get all the parts in one place. I like the larger diameter axle for rigidity, strength, and feel. The axle is also hollow which it makes light. No custom bearings etc either.

This is the trigger point: a person can go either way: Gas Gas wheel or Honda. Both have pros and cons. Right now if the gg wheel and brake can be made to work I will save money. RACE money.
 
As long as you have enough meat on the fork lug to play with. I'm still shocked to hear the lower clamps for the 48s are bored out 45 clamps, want to see that one for myself.
 
Yep. The non-brake fork is about 27mm, and the right side 20mm. The center of the bore looks the same for each side. That leaves 3.5mm roughly that can be bored. The forks should be here next week. Pretty excited to give this a shot and see what happens.
 
Think that the GG caliper will mount up or are you getting the caliper for the CRF forks? I am very interested in this project, wish that I had something to offer other that wishes for a good result.
 
GMP said:
I'm still shocked to hear the lower clamps for the 48s are bored out 45 clamps, want to see that one for myself.
Click to expand...

If I remember correct, this my clamp is from 2009 year GG. Part number has been change after that and maybe newer models clamp had bigger OD/material thickness. Could somebody measure the lower clamp OD from 2010 or 2011 bike?
 
Full fork rebuild kit is here. Bushings, orings, seals etc.
1.6 pressure springs will be here Friday.
Forks were shipped today. Should be here the end of the week.

Think I will leave the stock springs in. .47 is the rate. Start with 350 cc of 5wt oil.

Since my bike won't be ready I will do this to an 05 450R of my buddies to see how it all works for the weekend. The guy who had it before had it set at full soft rebound and compression. Crazy. Crazy it worked ok too. LOL. I reset everything and then tuned from there. It needs help for desert and enduro for sure. Not bad though. I tested a little section and was able to bounce it off the rev limiter in 5th and it took all the hits, big and small, without much worrying. The rocks are gnarly stuff is challenging on this stock MX bike, but you can feel the potential there.
 
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