Sealing front forks

[ritratto]

Hey all,

Rebuilt my forks  ('78 G5 with adjustable dampers and Wirth progressive springs and new top seals) about 3 weeks ago and both have started to leak from the bottom bolt. (one was pretty soon, the other just last night) Have new crush washers coming and want to know if there is a trick to making them seal well.

Thanks,
Ted

[oldbike54]

 I've had some luck with O rings and teflon tape .

  Dusty

[ritratto]

So Dusty,

Tape on the bolt and an o-ring the size of the bolt, under the crush washer?

[oldbike54]

So Dusty,

Tape on the bolt and an o-ring the size of the bolt, under the crush washer?

 Yeah , although crushing the washer can be tricky . I have a collection of fiber washers to use with a new washer . My old /5 had a teen einstsy little nick on the mating surface that almost made me crazy until using a magnifying glass to see it . A quick cleanup with a piece of emory cloth fixed the problem . Amazing what hydraulic fluid can leak past 

 Dusty

[canuck750]

You can apply thread sealant to the bottom fork damper bolt and the drain bolt along with new crush washers.

[Chuck in Indiana]

Well, I have some dead soft 3003 1/16" aluminum, and just make new crush washers because I can. 
Woo hoo! Emoticons worked.. 

[Antietam Classic Cycle]

I use a liberal application of Hondabond 4 to the underside of the bolt head and washer.

Might try some of these sealing washers on my project bike.
http://www.mcmaster.com/#93786A175

[oldbike54]

I use a liberal application of Hondabond 4 to the underside of the bolt head and washer.

Might try some of these sealing washers on my project bike.
http://www.mcmaster.com/#93786A175

 The stock BMW washers resembled those , never could find a source . Thanks Charley .

  Dusty

[drlapo]

My local AutoZone store has the sealing washers but I don't know if they have 6 or 8mm

[ritratto]

What kind of washers are you speaking of drlapo?

[tris]

The stock BMW washers resembled those , never could find a source . Thanks Charley .

  Dusty

isn't that just a Dowty Washer AKA bonded seal?

http://www.ebay.co.uk/sch/i.html?_nkw=dowty+washers

[mtiberio]

Happened to me recently. I simply took my air driver and rattled the heck out of the bolt. I assume it mushed the crush washer real good...

Cannot visualize how teflon on the threads would help...

[redrider]

Remember the Honda Hawk V twin? External oil lines with copper crush washers. Damn thing would start weeping after every service. New crush washers lasted a month or so. Drove Steve nuts and costly to replace for him. He was not happy. I used a butane pencil torch to re-anneal the old ones. Heat gently using a circular motion until the copper changes color to a rainbow bluish tint. Let cool naturally and install. Voila! No more leaks even with "used" items. I also did this to new ones and have never had a problem. Aluminium behaves similarly but I prefer copper.

[CT Dharma]

Hey all,

Rebuilt my forks  ('78 G5 with adjustable dampers and Wirth progressive springs and new top seals) about 3 weeks ago and both have started to leak from the bottom bolt. (one was pretty soon, the other just last night) Have new crush washers coming and want to know if there is a trick to making them seal well.

Thanks,
Ted

A timely post as I'm also in the midst of rebuilding front forks [springs, seals FAC dampers] on my SP; keep us posted on how you make out.

[oldbike54]

isn't that just a Dowty Washer AKA bonded seal?

http://www.ebay.co.uk/sch/i.html?_nkw=dowty+washers

 The original BMW washer was a bit different , I think .

  Dusty

[mtiberio]

Remember the Honda Hawk V twin? External oil lines with copper crush washers. Damn thing would start weeping after every service. New crush washers lasted a month or so. Drove Steve nuts and costly to replace for him. He was not happy. I used a butane pencil torch to re-anneal the old ones. Heat gently using a circular motion until the copper changes color to a rainbow bluish tint. Let cool naturally and install. Voila! No more leaks even with "used" items. I also did this to new ones and have never had a problem. Aluminium behaves similarly but I prefer copper.

actually you quench copper or aluminum to soften. opposite of iron alloys.

[ritratto]

A final update after a month of riding. Still sealed well. Stock washers from M.G. Cycle and some thread sealer.
I did do the initial torque and then let it sit overnight and re-torqued before reassembly.

[charlie b]

I use a liberal amount of RTV on mine.  Has worked for 30k miles