Silver, if you need springs, yes, you are looking at about $400 and this would cover about everything. At this point, I doubt anyone would need any wear parts at all. Maybe someone else can do it cheaper, faster, that’s totally fine with me. I agree, and fully understand the feelings of having to pay for this amount of work to make things right.
At this level, I don’t think there is a fork that’s "poor quality".
I also don't understand why some people consider Marzocchi a poor quality fork at all, or even the 48 Sachs mentioned. They’re just different; I don’t see a “cheap” component in them. Just because a fork is made a little different and it’s not what you’re used to seeing or working on does not necessarily justify it being “cheaply made”. It’s just different.
Usually the manufacturer of the motorcycle will spec out their parameters to the suspension manufacturer and they get exactly what they ordered. Don't completely blame Marzocchi or Sachs for what GasGas or any other manufacturer specs out in their design. Sometimes the suspension supplier and the motorcycle manufacturer work together (novel concept) for a set up. If it's off, they're both to blame. I wonder who (if anyone) did testing on the GasGas/Sachs fork.
Granted, there are some items within a Marzocchi fork that need more attention than others, but all said and done, the exact same things are also addressed on any other WP, KYB, Showa, Ohlins or any other fork.
With some knowledge of hydraulics and an understanding of ALL the circuits and how they affect each other, you can make any tunable fork do just about anything reasonable you want it to. Some (like the Sachs) have longer paths to success.
The engineers that design these forks do a pretty darn good job of it; they are manufactured and constructed very well with high quality materials. Could they do a better job in initial settings? You bet they should. I have witnessed some pretty bizarre practices being carried out the past several years with Marzocchi, and now Sachs takes it to the limit.
Who is responsible for the execution of that set up? What are they thinking? Do they test this stuff? Who is responsible for testing it and who gave it the green light? Not everyone is going to be in the zone they set it up for, but they should at least get it close.
If you look at a C/C KYB 48 unit (an improved copy of a 47 Showa) you might be surprised how fundamentally “back to basic” the design really is, same with their 48 Open units. These are out of the box, a very good set up with a broad working range. Are they right for everyone? Probably not but they sure hit a good target. Both Showa and KYB have made some real stinkers in the past too. Did we just forgot about, or possibly never experience them?
It’s too bad the Sachs fork is so far off, unfortunately, it’s more involved than thinner shims or magic valves.