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Fork Dampener Rod Wrench

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  • Fork Dampener Rod Wrench

    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
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    Grip it and Rip it

  • #2
    To notch the 8mm rod I placed it into my drill press and drilled it out until I reached 8mm.

    Ji
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    • #3
      This drilling thing notched the rod well enough to fit it up just nice.

      Ji
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      • #4
        I positioned the rods together using a welding magnet and tack it using TIG.

        Ji
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        • #5
          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
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          • #6
            I then lathed up an insert and pressed it into the nut with a 20 ton press. It all fitted up beautifully.

            Ji
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            • #7
              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
              Attached Files
              Grip it and Rip it

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              • #8
                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
                Attached Files
                Grip it and Rip it

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