‘66 Monza Jr - Fork Rebuild

[duck749]

Good evening, I am in process of rebuilding front forks. They are spongy and need a little TLC with paint cleanup and such. Currently forks are off the bike with dust covers unscrewed. I have measured the inner/upper fork tube as 30mm. The parts seem to follow the parts diagram I have. I am stuck with separating lower fork leg with upper tube. There looks to be a piece which threads into lower fork tube. If this is accurate, any trips on separating so I can clean and inspect remaining parts. The ID of the threaded piece looks to accept a tool like spanner wrench to unthread?

[DucMonzter]

It has been a while since I've disassembled the forks on my Monza Jr. but I seem to recall using a strap wrench to loosen the part you've indicated. The rubber strap was able to grab the external, aluminum threads without causing damage. You're probably correct in your assessment about the internal features accepting a spanner wrench but I was able to get mine apart without having any such tool. I've attached a coupe of photos that may be helpful.

- Jeff

[duck749]

Perfect thanks! Do you recall if normal threads and not some left hand thread?

I am in process of freezing fork assembly and then will use heat gun on lower leg in hopes I can get it free.

[duck749]

Finally got it off! Threaded out, little tight due to rubber stuck in threads.

Would like to post pic but keep getting error message for file size…

[Jordan]

We like photos.
Is your file too big?
Would you like guidance on how to shrink it?

[duck749]

Yes it’s saying to big, I use to use Shutterfly until they went to subscriptions. Any tips or info would be appreciated, I do use iPad if that makes a difference.

[themoudie]

Aye duc749,

I use Photoscape X for all my image twiddling and find it very good. Easier to use than GIMP in my opinion. Versions for both Windows 10 and Mac, I use the former.

Link to Photoscape website: Photoscape website

I hope this helps.

Good health, Bill

[ducwiz]

I use https://riot-optimizer.com/ for effective shrinking of .jpg and .png pictures/photos. It is also available as plugin https://riot-optimizer.com/dll-version/ for programs like XNView, XNViewMP, Gimp2, IrfanView <v.4.58

cheers Hans

[duck749]

Ok let’s try this, here is the start of disassembly. Debating on powder coating lower tube and headlight holder:

[duck749]

And have the parts cleaned up, parts list figured out and working with Sonic Springs for replacement springs.