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Posted: May 14, 2021 at 23:59 Quote
Enjoy, and let us know if you have specific questions.

Posted: May 15, 2021 at 12:47 Quote
rosemarywheel wrote:
I am not sure if this is the best place to ask this either, but I cannot for the life of me find out how fork stanchions are made. Does anyone have any info on this? I can make educated guesses but would love to find a video or article. Maybe I need a different search engine.

They are extruded aluminum tubes that get threaded and a coating process applied to them.

Posted: May 15, 2021 at 16:19 Quote
NorCalNomad wrote:
rosemarywheel wrote:
I am not sure if this is the best place to ask this either, but I cannot for the life of me find out how fork stanchions are made. Does anyone have any info on this? I can make educated guesses but would love to find a video or article. Maybe I need a different search engine.

They are extruded aluminum tubes that get threaded and a coating process applied to them.

Well, ...Yeah. I hope I don't sound too much of an @$$ but I knew that. I know enough about manufacturing to guess that much. I am looking for something a bitmore specific.

What does the machine look like? is it cold or hot when it is extruded? how is it cooled without any bending or warping? Tolerances? is it polished after the extruding? heat treat or no? thickness of walls? are they he butted tubes? what does the extursion part of the machine look like and function? (the jaws)

Or better yet, just finding a place to make 'em for me would be grand. Avalanche suspension was no help at all, I am going to try Fox, DVO and RS next.

Posted: May 15, 2021 at 22:55 Quote
What exactly is your goal? If you want to extrude your own profile then you're better ready to invest 10 grand in tooling.
I also think they are ground after extruding to get a better surface finish and tolerances. They also might be tapered in the crown so in that case it will become quite complicated. But for a set of one ofs you can do some stupid machining that wouldn't be economically viable for large scale.

Posted: May 15, 2021 at 23:08 Quote
SleepingAwake wrote:
What exactly is your goal? If you want to extrude your own profile then you're better ready to invest 10 grand in tooling.
I also think they are ground after extruding to get a better surface finish and tolerances. They also might be tapered in the crown so in that case it will become quite complicated. But for a set of one ofs you can do some stupid machining that wouldn't be economically viable for large scale.

I am going to make a chassis for a yet-to-be-created set of lowers and bridge machined by myself. I do have to wait until I can get back into the shop at school to use the lovely CNC lathe but I have Solidworks so I may as well design now.

There are sets of older Fox Fork Stanchions (New Old Stock) here on PinkBike so I may just buy those. I was just hoping to find an option of acquiring more if the guy on PB doesn't have more.

https://www.pinkbike.com/buysell/2672468/

I want something that is bombproof and the oldschool look like a Monster T (and the quality, of course) but with much more modern dampening. I will be throwing in either a Avalanche Damper (they do sell the damper as far back as 2005 for the Fox 40 stanchions I am enquiring about) and I can use Fox o-rings and seals. The reason for choosing (besides the bombproofness of the Monster) design is because the bridge and lowers are machined separately, instead of one piece. Once I found out about that, it became much easier in my mind to potentially manufacture one.

If it works out, and people like them, I may make more at peeps request. And I know of a guy who could paint them for me... https://www.maderad.com/
Or I can get custom stickers made. But paint is preferable.

i basically didn't want to depend on NOS Fox stanchions in case I ran out. I can of course get them elswhere, but it was the principal that counts. And knowing exactly how something is made somehow helps me design the rest even if I have no intention of making that part... but I cannot find any info on it Frown

And I am after Anodized stanchions only, no nickel plating.

Posted: May 15, 2021 at 23:31 Quote
Bravo for your commitment, but that's now how I would recommend doing it.

Even fork "manufacturers" don't exactly make their own. In most cases, they're just a standard OD & ID, maybe with a custom surface finish. Just go to a small motorcycle fork manufacturer and ask to purchase their stanchions or buy a few damaged Fox 40s and scavenge their stanchions.

If you get your own custom finish (try really hard to avoid it, but if you insist ...), it's the bushing vendor you want to talk to about tolerances.

Are you aware the Super Monster was just Marzocchi's moto trials fork with one of the two damper cartridges removed? Just do that. Buy whatever the MOQ (minimum order quantity) may be to get OE pricing - I'm guessing 50ish - make a tiny modification, and there you go: Super Monster v2.0.

Posted: May 15, 2021 at 23:56 Quote
Didn't one of the aftermarket suspension mod companies make replacement stanchions for Boxxers / 40s? Thought it was Fast, can't find any evidence on their website though.

Posted: May 16, 2021 at 5:45 Quote
You can buy fox 40 stanchions individually through any fox dealer

Fox part number 208-05-186 for the kashima 29er ones

I have a set of sorta scratched black ano ones laying around

They're butted and have a snap ring groove at the bottom. Lmk if you want some measurements

I'd assume the same for rockshox

IMO they're probably extruded, butted, snap ring grooves/threads machined, then roller burnished or centerless ground for the OD/ID tolerance. Crazy amount of special tooling.

Posted: May 17, 2021 at 5:34 Quote
R-M-R wrote:
Bravo for your commitment, but that's now how I would recommend doing it.

Even fork "manufacturers" don't exactly make their own. In most cases, they're just a standard OD & ID, maybe with a custom surface finish. Just go to a small motorcycle fork manufacturer and ask to purchase their stanchions or buy a few damaged Fox 40s and scavenge their stanchions.

If you get your own custom finish (try really hard to avoid it, but if you insist ...), it's the bushing vendor you want to talk to about tolerances.

Are you aware the Super Monster was just Marzocchi's moto trials fork with one of the two damper cartridges removed? Just do that. Buy whatever the MOQ (minimum order quantity) may be to get OE pricing - I'm guessing 50ish - make a tiny modification, and there you go: Super Monster v2.0.

Nope! I guess I will look into moto forks. What are the good brands? I don't dirt bike.

Yeah, I don't intend to get custom finishing- but I was thinking that maybe lazer engraving might be cool? Do you think that would be a problem?

Posted: May 17, 2021 at 5:35 Quote
secondtimeuser wrote:
Didn't one of the aftermarket suspension mod companies make replacement stanchions for Boxxers / 40s? Thought it was Fast, can't find any evidence on their website though.

I will poke around, Thanks! I haven't heard of Fast before.

Posted: May 17, 2021 at 5:37 Quote
thelibrarybiker wrote:
You can buy fox 40 stanchions individually through any fox dealer

Fox part number 208-05-186 for the kashima 29er ones

I have a set of sorta scratched black ano ones laying around

They're butted and have a snap ring groove at the bottom. Lmk if you want some measurements

I'd assume the same for rockshox

IMO they're probably extruded, butted, snap ring grooves/threads machined, then roller burnished or centerless ground for the OD/ID tolerance. Crazy amount of special tooling.


Measurements would be great, Thank you. Length, internal diameter at each end, and if you could shine a light down there and see if they look butted would be fantastic Beer

Posted: May 17, 2021 at 8:55 Quote
You're remaking the super monster? As a subscriber of the official huck bike appreciation thread, I applaud you.

Posted: May 17, 2021 at 17:15 Quote
Yeah, but if he's remaking it from scratch, I pity him. Even Marzocchi didn't make the original Super Monster from scratch!

Posted: May 17, 2021 at 17:18 Quote
To be honest I would question myself on what it is going to do better than any of the current offerings....

Pretty weird project

Posted: May 17, 2021 at 18:54 Quote
mediocrityontwowheels wrote:
You're remaking the super monster? As a subscriber of the official huck bike appreciation thread, I applaud you.

Well.... I want to start out with an 8" fork, then either a 10" or 12". I have asked Avalanche Suspensiion if I can get a custom damper that is longer. Really, because I don't have to make stanchions, seals, dampers if I don't want to, and the bushins, it's just a bunch of CNC work for the lowers/bridge/steerer tube and crowns.

Should be fun!


 
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