Fork Dampener Rod Wrench

[Jigantor]

I had to rebuild a set of Yamaha YZ125 H 1981 forks today. But first I had to make a T bar wrench to aid torquing up the dampener rod bolt.
I had some 8mm mild steel rod for the job and a nut that would fit into the dampener rod end.
The top of the damener rod has a socket end as per the following image.

Ji

[Jigantor]

To notch the 8mm rod I placed it into my drill press and drilled it out until I reached 8mm.

Ji

[Jigantor]

This drilling thing notched the rod well enough to fit it up just nice.

Ji

[Jigantor]

I positioned the rods together using a welding magnet and tack it using TIG.

Ji

[Jigantor]

I then continuously TIG welded up the T bar.
The dampener rod bolt has to be tightened up to 35N/m so I tested it to 45N/m, no problems.

Ji

[Jigantor]

I then lathed up an insert and pressed it into the nut with a 20 ton press. It all fitted up beautifully.

Ji

[Jigantor]

I continuously TIG welded up the nut assembly.
I used a Lanthanated electrode today just to see how they work, pretty good it carried the current fine.

Ji

[Jigantor]

When the new T bar wrench cooled down it worked great and the forks are already back in the bike ready to race tomorrow.

Ji