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F....ing appalling.
My other half picked up a very bargain priced set of unused 2009 Sid World Cups last weekend (badly injured racer flogging his kit to pay the bills)
First ride during the week, and it was pretty obvious they were leaking air between the +ve and -ve chambers - she lost about 20mm of travel in the first 15 minutes of riding.
So I pulled them to pieces this morning. Everything is covered in swarf - literally the (other wise clean) red grease is sparkling like a small girls cheap plastic jewellery. And then I found a pice of glass ~ 6mm x 10mm in the bottom of one of the legs.
Good, eh? 😕
Fortunately nothing appears to have been scratched or other wise damaged by the swarf, so with a bit of luck it'll all come out OK.
So if you've got a newish set of RS forks, I'd really recomend tearing them to bits cleaning them and swapping all the fluids as soon as you can, otherwise you could end up with a *really* expensive repair bill.
Or else buy your forks from TF Tuned - I understand they do all that before they send them out - arguably worth paying full RRP, rather than online discount price for the peace of mind.
Yes I've noticed that the assembly of them can be a bit hit and miss. Never found swarf, mind, but I've had them turn up with no semi-bath and over-full dampers preventing full travel (but then I've had that in 2006 'zocchis too)
olders zocchies used to be like this too.