Wow, from what I'd read online I was thinking I should just send the cartridge(s) away to have the seals replaced. Which would have been a complete waste of time and money.
I should mention that I do all of my own suspension work, I service my forks (both chambers) and replace the shock fluid every 20 hours of runtime. So far, the only job I'd farm out is a re-valve as there's just too much trial and error to do that on my own. So maybe if you've never had a set of forks apart, this job might not be for you ?
3 things I learned :
#1) This is far too easy to do, knowing what I know now I'd never even consider sending the cartridges away to have the seals replaced.
#2) There's no need what so ever to spend $59.99 + shipping on a shaft holder, not that it wouldn't be a nice tool to have, but completely un-necessary.
#3) ** MORE THAN LIKELY THE MOST IMPORTANT ** The thickness of the outer cartridge wall is approx. 1.51 - 1.6 millemeters thick, I more than likely didn't drill more than 1.4mm into the dimples. I'd drill for 2 or 3 seconds, then look at how far I'd gone, then drill 2 or 3 seconds and look. I did that until I thought I'd gone deep enough - Keep in mind you only need to go about 1.5mm.
Here are some pics :
At this point I'd already had the seal head out, before I'd had it out the drill mark looked uniform and I couldn't really see the threads. I used my 2lb propane torch to apply some heat before I put the allen wrench on, I spent about 2 minutes warming the cartridge.
Bought this 17mm allen head wrench for $22
Edited by crf450319, 01 April 2011 - 11:07 AM.
Added some info.