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  1. #1
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default 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. #2
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default

    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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    Grip it and Rip it

  3. #3
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default

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

    Ji
    Attached Images Attached Images
    Grip it and Rip it

  4. #4
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default

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

    Ji
    Attached Images Attached Images
    Grip it and Rip it

  5. #5
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default

    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
    Attached Images Attached Images
    Grip it and Rip it

  6. #6
    Join Date
    Jul 2009
    Location
    Australia
    Posts
    1,029

    Default

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

    Ji
    Attached Images Attached Images
    Grip it and Rip it

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