Precision machining required

[mangocrazy]

Maybe I’m being dumb here. But I’d reckon there’s got to be someone on here who could make that from scratch for you from a billet of aluminium.

I was rather hoping that might be the case...

 

[Brad93]

I think you’d need to have the original and see if the casting could be replicated to your needs, add more meat between the seals you are talking about then thread it the right thread for you rather than bore it through. A thread is going to have more meat and be stronger than an oversized bore.

 

[Shox Dr]

Are you saying WP doesn’t make one either?

 

[mangocrazy]

I think you’d need to have the original and see if the casting could be replicated to your needs, add more meat between the seals you are talking about then thread it the right thread for you rather than bore it through. A thread is going to have more meat and be stronger than an oversized bore.

The casting wouldn't be simple to replicate on a CNC - at least it doesn't look simple to me. Remaking the sleeve to the correct size and with a thread to match my shock is what I'm intending to do. And fabricating it in decent steel should give it more strength than ali.

 

[mangocrazy]

Are you saying WP doesn’t make one either?

Nope, I've been in touch with the factory and they confirm they don't have a fitment for that shock. Bizarre.

 

[Shox Dr]

Nope, I've been in touch with the factory and they confirm they don't have a fitment for that shock. Bizarre.

I cant believe they make a shock tube especially for KTM. It will be a standard diameter available in different lengths to suit different applications.

 

[mangocrazy]

I cant believe they make a shock tube especially for KTM. It will be a standard diameter available in different lengths to suit different applications.

KTM own WP. Have done since the mid 2000s. WP do whatever KTM want. WP are standard fit on every KTM bike.

 

[Shox Dr]

KTM own WP. Have done since the mid 2000s. WP do whatever KTM want. WP are standard fit on every KTM bike.

Are they not fitted to others

 

[mangocrazy]

Are they not fitted to others

Not as OE. You can get WP aftermarket shocks for a number of bikes but they've only just started going for the aftermarket again. For the last 10-20 years they've just mainly been KTM's in-house suspension people. KTM even moved them from Holland to Austria. A lot of the original WP folk baulked at that and set up Tractive suspension, still based in Holland. Back in the 80s and 90s they were regarded as on a par with Ohlins.

 

[Brad93]

You’re going to want a piece of EN19 or EN24 steel I reckon to make a new sleeve.
Nice and easy to turn plus a lot stronger than mild steel.

Not sure what you can do to it to stop it rusting. Nitriding prehaps. Satin chrome.
Or 303 stainless. Easy to turn and reasonable corrosion resistance - not particularly strong for a thin sleeve.
Duplex?

 

[Wallace]

If that preload adjuster is not geared, how does it work hydraulically? Looking at the photos, removing thread has left you with no preload adjustment as the unit relies on the thread to apply load on the spring.

 

[mike os]

Just get a cylinder hone and get on with it .... its hardly high precision work...Just needs to be a close fit,

 

[mangocrazy]

You’re going to want a piece of EN19 or EN24 steel I reckon to make a new sleeve.
Nice and easy to turn plus a lot stronger than mild steel.

Not sure what you can do to it to stop it rusting. Nitriding prehaps. Satin chrome.
Or 303 stainless. Easy to turn and reasonable corrosion resistance - not particularly strong for a thin sleeve.
Duplex?

I've used ENP (Electroless Nickel Plating) in the past - good corrosion resistance and lubricious (i.e. slippery). Would be ideal for that purpose.

 

[mangocrazy]

Just get a cylinder hone and get on with it .... its hardly high precision work...Just needs to be a close fit,

You haven't read all the way through the thread, have you?

 

[mangocrazy]

If that preload adjuster is not geared, how does it work hydraulically? Looking at the photos, removing thread has left you with no preload adjustment as the unit relies on the thread to apply load on the spring.

Some hydraulic preload adjusters have an internal thread, most don't. Ohlins and Sachs don't. They have a grub screw or similar to locate them during assembly and once the spring is on, it isn't moving. On this WP unit, I'd insert the tongue on the external casting into a castellated collar and lock it into position onto the other one.

 

[Wallace]

Some hydraulic preload adjusters have an internal thread, most don't. Ohlins and Sachs don't. They have a grub screw or similar to locate them during assembly and once the spring is on, it isn't moving. On this WP unit, I'd insert the tongue on the external casting into a castellated collar and lock it into position onto the other one.

Is the inner part you have removed the thread from a piston?

 

[mangocrazy]

Is the inner part you have removed the thread from a piston?

The inner is static, the exterior casting moves downward to apply preload to the spring. Not sure which part you'd refer to as the piston.

 

[Wallace]

The inner is static, the exterior casting moves downward to apply preload to the spring. Not sure which part you'd refer to as the piston.

The outer being a bore and the inner a piston.

Similar setup to my Speed Triple except that uses a remote to provide the hydraulic pressure.

 

[mike os]

You haven't read all the way through the thread, have you?

Yes...it needs to slide over the threaded section.... its not rocket science

 

[mangocrazy]

Yes...it needs to slide over the threaded section.... its not rocket science

And you still haven't read all the thread, clearly.