Just a small example of why I don't relish telling every DIYer out there how to do so.
This rolled in this AM, nice work, eh? ;)
See one or two of these a month, and due to the mentality of the average DIYer, they aren't often happy with the bill if you know what I mean!
Why I don't try to fix my computer, car, plumbing, whatever, I don't want to be the guy that cost himself more, trying to save himself some.....
Aaand part 2.....
If you're gonna go, go big!
Wow... that's insane.. looks like somebody used a tin-opener from a swiss army knife for that one..!!
Don't even get me started on a guy from Canada's RLC, whole thing had been "expertly and fully serviced" prior to sale on eBay, did the whole thing with a pair of Vice Grips...... :madman:
Originally Posted by Mac the Knife
Yeah, DIY gone wrong, been there, seen that. :eek:
What's wrong with it? Looks fine to me.... ;)
Originally Posted by MendonCycleSmith
Hello guys. I'm making a custom foldable ebike with 12" wheels. I needed a small suspension fork and cannondale headshok seemed the only one that is possible to shorten by 7 inches. So I looked for dirty cheap fork to play on. And here it is, £20 worth of 1999 Super Fatty M:
It seemed kinda okay (but very fast rebound), but I took it apart anyway, just to give it a fresh start. And what would you know, I noticed a few things that are so wrong... Someone has already messed with it.
1. First thing I noticed is that both elastomeric tubes are next to each other, sitting between piston  and cartridge cap . I was able to find a service manual on MC50/MC60 (this one is MC80) and, according to it, smaller one goes on top of cartridge cap . Is this correct?
2. There was a small piece of aluminum foil  laid inside the groove of piston . On top of it were two rubber rings  and . On top of those was a plastic wear ring . I assume the foil  was added by someone to compensate on ring  wear. Despite that, is this correct?
3. Cartridge cap  is a mystery. When I removed it, rubber ring  (badly crushed) just fell off, no idea where it should go. I guess it must be rolled on the top most of the cap (marked with two red lines), to seal the cartridge. But there is a problem: raceway retaining clip  does not fit properly on to the cap  and does not go all the way to the top, which means no sealing on the cartridge possible... And on lower part it is too loose. Also there is one unexpected part - steel ring . It looks like a custom (poorly) machined part. Internal diameter is the same as raceway retaining clip , thickness as well. And yes, it does not fit on top of cartridge cap's step up to red lines.
To me this looks like some parts came from different fork... How should it all fit together?
P.S. if all goes well, I will machine the piston rod and replace seal , but this puzzle has to be sorted out first...