so i just got my brand spanking new 2010 rock shox boxxer team in the mail today and upon just cycling the the fork through its travel a couple times a strange grinding noise had occurred in the right leg. upon further inspection, the sound seemed to have come from above the powerbulge section...
pull it apart! when i get a fork, new or used, it gets pulled apart, cleaned, inspected, filled with maxima oil, slick honey on the seals, and new crush washers (i have a "tackle box" from rockshox, i do all of my own suspension service except for seal and bushing replacement).
Then it gets re-assembled and put to use. A fork like that is an investment, and i'm not gonna trust a company to do it right, no matter how good their reputation.