Day 4

We had the new front forks and triple clamps to test-fit today.  We also double-checked the clutch operation with the new parts from Transcanada.  We didn't take any pics today, as Heidi came by from the Minnedosa Tribune to do a story on the bike project.
We put the front end on and things mocked up properly.  We then removed the fork tubes in order to rebuild those.  It is obvious we need to do something with the fork lowers, but at least the upper tubes, the sliders, were in good shape.  After some discussion, I think we will either polish the lowers or get them powder-coated.  We might need to do a vote or something!
One fork came apart pretty easily, but the other tube was far more stubborn.  We ended up calling it a day (at our usual stop time) with one fork disassembled, and the other still stubbornly in one piece.  What we realized is we needed a 17mm Allen wrench -- we actually did have one -- but one that was about 2 feet in length.  Mr. Sheppard took the fork home to see if he could come up with something.
Rooting around in a scrap bin, a 17mm domed nut and a length of threaded rod (wrong thread size, however) were dug up.  A wee bit of welding with the oxy-acetylene kit, and a new tool is born.

A good lesson.  Sometimes, you just have to stop and think about things if you are getting nowhere.    It is too bad the two students weren't around when the tool was made, or used successfully to finish the disassembly.  We'll be sure to look it over tomorrow or at the next session to see how with some ingenuity, we can solve a problem.  Certainly nothing like what you would see on American Choppers, but it worked a treat!