DIY fork bushings

Anyone done it? I’ve done pretty much everything else on a fork, and I’ve also honed some too-tight ones before.

Experiences? Fox 32 circa 2013 100mm if it matters. I will replace the seals at the same time so they’re compatible with Fox Gold, which the old seals weren’t.

Interested to see how it goes…. think mine are 2014 Factory

I never quite understood which seals are the ones that need upgrading to use Fox Gold TBH.

You can tell by the colour, but I can’t remember which colour is which.

I have only replaced them with the “proper” tools.

I would be quite happy to bodge it at home on my own forks. They are just a press fit, need to be pulled or knocked out, then pulled or pressed in. There are a few variations on the “proper” tools to do it, the Fox and Andreani use expanding collets with a lip to grab the bush very evenly. Andreani uses a thread and receiver tube to pull the bush out, I think Fox uses a slide hammer. BLL do a hammer out tool that is like a mini headset cup removal too. Andreani draws them in through the footnut holes with a threaded rod.

There are old threads on MTBR using a washer with flats filed on it to act as a toggle to pass through the bush then hook it, can be used with a slide hammer or threaded bar and a receiver tube. A couple of videos on youtube now as well.

Just depends what tools/scrap you have available and ability to make or bodge bits up. Make sure you measure the bushing height, or do one side at a time so you can copy.

Flanged seals are the old ones, the new seals are flangeless.

I might try 3d printing something.

You can tell by the colour, but I can’t remember which colour is which.

So is it only the wiper seals?
I really need to service the 32’s… and I have litres of Fox Gold… (Its 100ml 20wt in the smashpot on lyriks and 90ml on Zebs) and the charger seals well enough to bung it in that side as well.

Flanged seals are the old ones, the new seals are flangeless.

I’m still missing something here… what happens to the flanged wiper seals if you use 20wt in the lowers?
Do they swell up? disintegrate etc.??? hence is it only the wiper seals or internal seals as well?

I did it years ago on a pair of old marzocchis, marathon coils I think.

That was mainly using the power of bodge. I am not sure I would try on a very modern pair of forks as everything seems a bit less industrial and forgiving now.

Iv done this quite a lot
Will post some pics of the tools I made
Nothing very complicated

I might try 3d printing something.

I’d be interested in how this turns out.
I can’t see most standard filaments suiting this, I discovered that igus do make a couple of FDM filament the other day which may be worth a look.

I’d typically expect to turn a bush from nylon or delrin but if it’s got thinner walls or other fun features 3D printing might be a good idea…

I can’t see most standard filaments suiting this, I discovered that igus do make a couple of FDM filament the other day which may be worth a look.

when I read that I assumed he meant 3D printing a removal tool?

Cant find my tools, pretty sure I know who i loaned them to!

I bought the bushes from Mojo when they had the Fox stuff in the uk, for the 32mm stanchions there are 2 lengths of bushes for the top and bottom position in the lower legs.

They used to be about £20 for 4 bushes, but its a long time since Iv had Fox 32`s on a bike! I may still have some.

The genuine Fox 32 lower leg bushes are only £30 for a full set. Definitely not worth the risk of damaging a fork by trying to make your own.
Fox part number 803-00-102

Yes I meant 3d printing a tool, not the bushings!

I might need to reinforce the tool with metal bits. Or I’ll just use the washer method. I think I might’ve done this before to move bushings as someone suggested you could adjust the tightness that way.