17 - Appendix 2
Make your own tool
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It is possible to make the fork tool yourself. I built the one I was shown using in this article, the
original from which it was styled, designed and built by Duane Ausherman. It is made from a section of lower fork bracket from a wrecked bike (one bracket makes two tools). I simply sawed off the end of the bracket on my table saw using a carbide blade and then used a die grinder and sanding belt to clean things up. The rod is a long BMW cylinder stud which just happens to have the same thread size as the pinch bolt that originally resided in the bracket's threaded hole. Then using a scrap of steel, I just brazed the lug onto the rod (it can also be welded) and drilled and tapped a 1/4"x20 hole for a bolt and nut to affix the dial indicator's lug back.
An easier solution might be as shown in this drawing. A top view is shown here. Use a piece of heavy-walled angle iron in aluminum about three or four inches long, cut one face to be roughly at 90 degrees to the fork tube. Drill and tap a hole to accept a standard type dial indicator mount as shown. Use a 1" travel .001" tolerance indicator. If such heavy stock cannot be found it could be made by bolting together two pieces of aluminum stock to form the 90 degree bracket section as indicated in teh drawing. Do not use steel for this part as it might scratch the fork tubes.
Although this design might be a little more difficult to use, it would be easy to build using not much more than a drill press and a set of taps for threading the holes. It would be particularly good for someone who already owns a dial indicator and the various mounting options for it as shown here (lug back, threaded rod, sliding mount). It would also be useful on a multitude of fork sizes as the diameter of the tubes would not make much difference and the dial indicator could be easily adjusted for various tube spacings.
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