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Fork tube repairs

Posted: Thu Jan 23, 2020 8:59 pm
by Gary B
Hi Folks,
I’m trying to help a friend but their first Trials bike and $$$ are a little tight.
We’ve found a Gasser that seems ok, but both fork tubes have scratches. It has Marzocci forks with the black nitrate coating.
Has any body out there been able to repair the scratches or had the tubes recoated.
New inner tubes are over $300 each.

Any feedback appreciated


Re: Fork tube repairs

Posted: Thu Jan 23, 2020 9:08 pm
by gasgasman
I dinged one once. Just filed the high spot back and filled the hole with epoxy. Held up well which was good coz 10 years ago zoke fork leg tubes were more expensive. Over $500 per side back then.
Have you priced up jitsie legs? If I remember correctly they are significanrly cheaper again than genuine

Re: Fork tube repairs

Posted: Fri Jan 24, 2020 8:05 am
by Gary B
I can’t find Jitsie legs to suit Marzocci forks, only Tech forks.

Re: Fork tube repairs

Posted: Fri Jan 24, 2020 11:41 am
by gasgasman
My bad.....must have got my wires crossed on that one :shock:
I'll get off the drugs one day...

Have you tried Trials bike breakers in the uk? There is also another trials wrecker over there but their name escapes me atm

Re: Fork tube repairs

Posted: Fri Jan 24, 2020 1:59 pm
by bforsyth
As gasgasman mentions, for minor scratches, you can get away with filling with an epoxy or even nail polish and sanding smooth with very fine grade wet and dry.

There are plenty of places around that can do re-chroming, but I don't know how cost effective it is.

Re: Fork tube repairs

Posted: Fri Jan 24, 2020 3:27 pm
by gasgasman
These forks are anodised aluminium making them a far more expensive repair.

Dunno is Marzocchi even still going? Last Id heard they had gone belly up.

And I remembered the name of the other Uk wreckers.
Just google Allens used trials spares

Re: Fork tube repairs

Posted: Fri Jan 24, 2020 3:56 pm
by paulm
Hey GB - you can certainly make them serviceable - nicks and scratches can be filled with 20 Super glue - it's thick stuff not the weedy stuff from Bunnings I import it from the US. you can get it here: ... _Glue.html

Just need to make sure the scratch is grease free and then rub it back with 1200 grit.


Re: Fork tube repairs

Posted: Tue Jan 28, 2020 7:20 pm
by Gary B
Thanx Paul,
I never knew you could get coloured superglue.
Ash has paid for the bike & we should see it up north this weekend.
I'll be able to see how bad the damaged legs are then.


Re: Fork tube repairs

Posted: Wed Apr 29, 2020 10:38 pm
by bikerpete
JB Weld is a really good metal filled epoxy filler. It also lasts in the tubes almost for ever - I've got some ratty old tubes here that must be a good 15 years old and they're still OK!

Another good trick is sodium bicarbonate and super glue. Sprinkle a bit of bicarb into the scratch then drip in the super glue. The bicarb makes the super glue go hard instantly. Sand back and all's well, or a bit of nail polish to colour it. If filling something really deep do it in thin layers or the glue will set before it sinks into the powder. I've never had much joy doing it the other way - glue then powder. I used to repair aircraft props with this.

Q-Bond kits are available several places - it's basically a couple of bottles of good super glue and a couple of bottles of coloured bicarb/filler (grey & black). The filler works with any super glue I've tried it with.

Re: Fork tube repairs

Posted: Thu May 07, 2020 5:38 pm
by Gary B
All fixed up now.
I had to file down gouges in alloy legs in a few spots.
I was advised to get some black Stewmac superglue from USA.
Thanx Paul :wink:
The stuff is great.
Took a few goes to fill with glue, wait to dry, file off excess glue round scratch, then redo to get damage filled really well.
There was 3 different places with lots of deep scratches in the Black Nitrate & alloy.
Image is of just one repaired area I repaired to give you all an idea of how well this glue worked.
New seals and no leaks.
My son's girlfriend is happily riding her Gasser now :D

Gary B