Its not like a clunking but more like a spring in an old vanilla making a graunch. It happens through a range of about 10-20mm of the travel half way through its travel. A kind of dull noise/feel. Not metal on metal noises.
Given that had said not exceed 100psi would you not check the pressure inthe fork when you got it back after repair?
No, I rebuilt the bike and once everything was complete I pushed down on the bars before taking it for a spin outside and first felt the problem in the shed. I am not a fan of pushing forks down off the bike, it can damage top caps on delicate rods and also rebound adjusters if they are pressed into the floor. I have seen a few rockshoxs damaged by people doing this. Leaving the lockout lever slightly canted.
So there was no reason to go inflating it before refitting. I felt the problem and decided it was coming back off the bike and back into the box. I had no plans on messing around with pressures or rebound when it felt like it did. Like I said, I cycled it a heap of times to no avail and left it at that. Off it came!
Its a fit 140 rl.