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I somewhat disagree. The extension caps are a simple beginner lathe job, any lathe is capable of it. You'd need a boring head for the mill to bore the triple clamps and there's more risk if you blow the dimension and scrap the part. Not a big deal either way though.

Next on my list: footpeg lowering brackets!
Foot pegs lowering brackets........ I want some 😀
 
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The spread won't allow for the wider TW200 front wheel I would suspect.
The triple tree is steel? Didn't know that. When I honed out my case for the kick starter, I used a sanding drum. worked great. I imagine it wasn't perfect, but since the forks are clamped on the inner tube, not the outer, no worries about inner/outer stiction from a slight warp or non-compliance fit. As long as they clamp the forks up that high with nothing but a spring inside, it should be fine. I may fill gaps with some sort of filler. Perhaps Liquid Steel with a Saran Wrap around the fork tube while it sets. Then remove the fork, Saran Wrap and reassemble. I could index the upper to the lower that way when I set the epoxy with the fork tube as well.

I would prefer the fork extensions if meatshield gets around to milling any. I don't have a problem with the stock forks, just that I'm running an ATV tire and have a 2" extended swingarm I'll be swapping in once my TTR225 motor is ready to transplant.
A 21” front wheel would make the bike taller as well. :)
I hope I am not banned for such blasphemy.
 

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A 21” front wheel would make the bike taller as well. :)
I hope I am not banned for such blasphemy.
Not as tall as you would think. Photos of the TW200 and TTR225 side-by-side: (TTR225 may need preload set a little stiffer)
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What do you think about a sanding flap wheel to open up the 33mm to 35mm? What grit would be recommended? They come in a 40 all the way to 600 grit. Sizes include 1.6" and 2" diameter. I think 1.6 would work, but 2" would be a tighter fit and likely cut faster. All thoughts and opinions appreciated.
I've removed a lot of steel material using a right angle grinder with a flapper disc, but not a drill-style flap wheel.
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Here's my plan, a big ol' reamer o_O!

View attachment 226335
I was eying this adjustable reamer but was wondering how to tool the handles. Your photo explains that. THANKS!
EDIT
Oops! I need two of them since this one doesn't go down to 33mm where I need to start and the next size down won't go up to 35mm.

EDIT
Another edit; found both H13 and H14 on eBay for total of under $50 for both including ship and tax. Hmmm....

EDIT
and still another edit. The description kills my idea, "They are also restricted to usage unbroken holes. If a hole has an axial split along it, such as a split bush or a clamping hole each straight tooth will in turn drop into the gap causing the other teeth to retract from their cutting position."
So these won't work.
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@Snow Fox , I recently sold my tricked out XT225 to replace it with the TW. I really enjoyed the XT, it was a good bit lighter and seemed a bit more road and off road worthy From what I can tell from the TW. The TW is a little more simple bike which I like. Also, the Trail Way is so different, it makes a lot of people smile. one of my good friends and riding buddies wants his wife to start riding and I put a little smaller tires on the XT (MT21s one size down from stock sizes) and it was too tall for her. The TW is also too tall. The TW is a bit wider but they are similar height wise. The additional suspension travel of the XT was kinda cool considering its seat height to ground clearance specifications. I sure didn’t need both of those bikes since they covered the same “use“. I have some other bigger bikes and some smaller. It’s hard to not just keep growing the stable. I like all motorcycles!
 

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@Snow Fox , I recently sold my tricked out XT225 to replace it with the TW. I really enjoyed the XT, it was a good bit lighter and seemed a bit more road and off road worthy From what I can tell from the TW. The TW is a little more simple bike which I like. Also, the Trail Way is so different, it makes a lot of people smile. one of my good friends and riding buddies wants his wife to start riding and I put a little smaller tires on the XT (MT21s one size down from stock sizes) and it was too tall for her. The TW is also too tall. The TW is a bit wider but they are similar height wise. The additional suspension travel of the XT was kinda cool considering its seat height to ground clearance specifications. I sure didn’t need both of those bikes since they covered the same “use“. I have some other bigger bikes and some smaller. It’s hard to not just keep growing the stable. I like all motorcycles!
I was actually considering an XT225 or a KLX 250. The TW sure is a magnet for bike lovers. Yesterday I rode to town to get my mail and the Dubs drew a small admiring crowd. Actually a thief was among the folks because someone stole my lunch money out of my pack, which I had left on the bike seat when I used the lady's room at the gas station. Afterwards I treated myself to a burger at the local cafe and realized what happened when I couldn't pay the bill. Thank goodness a gentleman at the next table kindly paid for me. 😇
You got road bikes too? 🤩
 

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I was actually considering an XT225 or a KLX 250. The TW sure is a magnet for bike lovers. Yesterday I rode to town to get my mail and the Dubs drew a small admiring crowd. Actually a thief was among the folks because someone stole my lunch money out of my pack, which I had left on the bike seat when I used the lady's room at the gas station. Afterwards I treated myself to a burger at the local cafe and realized what happened when I couldn't pay the bill. Thank goodness a gentleman at the next table kindly paid for me. 😇
You got road bikes too? 🤩
Sorry that happened..
I do not have a vocabulary sufficient enough to tell you how much I despise a thief .
It should be legal to castrate and hang them in the town square ...
mike from NC
 

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