Five Strip & Rebuild, ready for spring
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George



Joined: 28 Jul 2009
Posts: 182
Location: York

PostPosted: Sun Jan 19, 2014 10:07 pm    Post subject: Reply with quote

Sweet mate!! It's good to get involved with your bike.

I have just sent my 5 to powder coaters. Servicing floats as I type!!
I am going to a couple of nice new shiny bits but clean and service the other stuff!!

I will start my own thread, going to do my specialized too!!
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Sun Jan 19, 2014 10:55 pm    Post subject: Reply with quote

George wrote:
Sweet mate!! It's good to get involved with your bike.

I have just sent my 5 to powder coaters. Servicing floats as I type!!
I am going to a couple of nice new shiny bits but clean and service the other stuff!!

I will start my own thread, going to do my specialized too!!


Couldn't agree more george! I like to think that I can do most things on it myself rather than trust it to someone else!

What colour are you having it done? I'll look forward to your thread, gotta love the five!

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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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George



Joined: 28 Jul 2009
Posts: 182
Location: York

PostPosted: Mon Jan 20, 2014 11:35 am    Post subject: Reply with quote

I really ejnoy reading up on parts and upgrading my bike.

I bought a 2008 frame of ebay, it had just done road work really but was scratched (which was exactly what I was looking for) my Sub 5 is black, wit gold bits so after a massive decision I am going black again. Did consider, green & pink!! I do like the black and gold look. I am also considering stripping my Specialized and going matte black with new green stickers!!

Will share the link when I start thread, in next couple of days...
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Magnus



Joined: 18 Jan 2013
Posts: 1512
Location: Leicester

PostPosted: Mon Jan 20, 2014 2:41 pm    Post subject: Reply with quote

Hey Gaz, did I see you out around the lakes on Sunday morning? there was a Guy with a similar looking machine wearing a black full face helmet going clockwise around king lears.
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Mon Jan 20, 2014 6:10 pm    Post subject: Reply with quote

George wrote:
I really ejnoy reading up on parts and upgrading my bike.

I bought a 2008 frame of ebay, it had just done road work really but was scratched (which was exactly what I was looking for) my Sub 5 is black, wit gold bits so after a massive decision I am going black again. Did consider, green & pink!! I do like the black and gold look. I am also considering stripping my Specialized and going matte black with new green stickers!!

Will share the link when I start thread, in next couple of days...


Good stuff!! Look forward to seeing your thread.

_________________
My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Mon Jan 20, 2014 6:14 pm    Post subject: Reply with quote

Magnus wrote:
Hey Gaz, did I see you out around the lakes on Sunday morning? there was a Guy with a similar looking machine wearing a black full face helmet going clockwise around king lears.


No wasn't me Magnus - its still in bits and will be for a little while. I can't ride for a bit following a small operation over christmas (nothing serious, won't boar you with the details!!). Nooooooooo two of them in the city?? Quite liked the rarity factor of it locally as well Very Happy
Did the fork today, took plenty of photos whilst doing it, so will resize and upload them later.

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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Mon Jan 20, 2014 11:46 pm    Post subject: Reply with quote

Right here we go then.... strip, change dust and wiper seals and lower leg oil on a fox float fork and then rebuild it. Surprisingly straightforward to do if you are a bit 'hands on'. If you have any doubts then leave alone and trust to the pro's, but if you are 'so minded' then here we go!!
Will do this in 'blocks' of posts, as I have loads of pictures and will be easier that way!!
Kit you will need.....
A bucket or large bowl -to empty/drain the old oil into
A workstand or workmate is handy, though not essential.
Some surgical type gloves if, like me you don't want to smell of fork oil!
A 2.5mm Allen Key.
A 10mm socket with extension bar and ratchet/T bar.
A hook or a pick.
A 19mm open end spanner (I used an 18 tbh!!).
A pin punch.
A narrow socket (I used a 3/16").
A hammer.
A large socket to fit over the new seals.
A syringe.
A shock pump.
A long bar (I used a long socket extension bar).
Brake cleaner.
Rags (clean!!!).
A small tub.
Your fork seal kit.
Some fork oil (In my case Fox 10 weight).
A thin screwdriver (Or any item to drain the forks air).
Some suspension grease.

I suppose I should do my H&S bit and say wear safety goggles, gloves, safety boots and a hi viz vest as I did Very Happy Very Happy Just set yourself loads of time to do this...as inevitably it will always take longer than you plan!!
Before you start, put your foam seals into the small tub and cover them with fork oil.

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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 1:01 am    Post subject: Reply with quote

Ok, So the air has been drained - you will actually see the fork 'compress' a little as the air all escapes it. Now, if we have something to clamp the fork with, turn it upside down and clamp it (careful not to damage any of that lovely paint! I clamped mine by the steerer tube, so no damage was done).
Once upside down, back off your rebound damping (all the way to the minus ' - '), As you back it off count the number of turns or 'clicks'. You will feel it lock up so stop backing off at that point.

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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 2:04 am    Post subject: Reply with quote

So the oil has all been drained out from the two parts of the fork that you now have.
Your first task is to take the new seals (the black ones - the foams are soaking in fluid still!) and give them a really good clean with a clean rag and some brake cleaner. Like anything made of rubber (tyres etc.) they will come out of the mould with some residue on that will need cleaning off. So its worth spending five minutes here giving them a really good clean.
Removal of the old ones is easy. Just bear down on your open end spanner with moderate pressure (shouldn't need too much) and they will pop out.
Once removed, give the inside of the lower legs a thorough clean by wrapping a clean rag around your long bar and using brake cleaner - do NOT use water or anything that will leave a residue - brake cleaner evaporates so is pretty safe. Was a pretty sunny day today, so left all of my freshly cleaned parts in the sun to let the brake cleaner evaporate. Tbh its worth giving all of those bits of the fork you can't normally get to a thorough clean whilst its in bits. Whilst cleaning it, have a look down into each lower leg - theres a washer that sits in the bottom of each - it can unseat on dismantling. Once you have cleaned the fork, using the long bar carefully push them back to the bottom of the lower legs making sure they are sitting flat.
To install the seals (the rubber ones!) Fox do a driver tool that is just over £30. it sits over the seal and with moderate pressure from your palm pushes the seal into place. I chose to use a socket - does the same job and FAR cheaper!! Take your time when doing this, don't rush or force the seals in... ease them in - slowly, slowly, catchy monkey!!! Make sure they are level and flush all the way round - this is IMPORTANT!!!

_________________
My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html


Last edited by GbGaz on Tue Jan 21, 2014 2:34 pm; edited 2 times in total
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 2:31 am    Post subject: Reply with quote

So everything is clean and the new seals are in. Time to put the foams in then - I have adjusted the exposure on pictures two and three... it makes for a crap picture overall but hopefully it shows the detail of the foams going in that we need to see.
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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 2:53 am    Post subject: Reply with quote

So with the steerer tube 'upside down' in the clamp/workmate/vice (delete as applicable!!) we are ready to put the two halves back together.
Initially, we are just going to 'start' the seals on the stanchions - just enough to create a seal.. we don't want to be pulling the threads through the holes in the lower legs just yet, the reason will become clear if you read on!!

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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 3:16 am    Post subject: Reply with quote

Almost done then!! Just the nuts to refit - we need to remove the old crush washers from the bottom of them first... just a case of flicking them out with a screwdriver or pick. The new washers are the little black ones in the service kit - to retain them i smeared a bit of grease between the nut and washer. The nuts can then be tightened down to the tension we felt earlier as we backed them off that half turn and retightened them.
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My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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George



Joined: 28 Jul 2009
Posts: 182
Location: York

PostPosted: Tue Jan 21, 2014 10:31 am    Post subject: Reply with quote

Awesome dude!! Well written and covers everything!!
I have never done any fork work, but split my floats 150's down the other day and sent the lowers to the powder coaters. I know what to so but you can guarantee I will have this thread open when I build them up.

Top work !!
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GbGaz



Joined: 17 Dec 2013
Posts: 193

PostPosted: Tue Jan 21, 2014 2:37 pm    Post subject: Reply with quote

George wrote:
Awesome dude!! Well written and covers everything!!
I have never done any fork work, but split my floats 150's down the other day and sent the lowers to the powder coaters. I know what to so but you can guarantee I will have this thread open when I build them up.

Top work !!


Thanks George!!

I tried to do it as a 'How To' for anyone that wanted to have a crack at doing their own.. they are fairly straight forward to do to be fair.
Should anyone have any questions regarding doing this or getting hold of the bits, feel free to message me.

_________________
My Five rebuild thread, with Fox Fork rebuild - come take a look!!
http://www.mtbe.co.uk/five-strip-rebuild-ready-for-spring-t43380.html
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mcfc1987



Joined: 24 Jul 2013
Posts: 718
Location: Lincoln

PostPosted: Tue Jan 21, 2014 2:57 pm    Post subject: Reply with quote

what an awesome write up! cheers man!
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