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Discussion Starter #1 (Edited)
Different forks on a TW...what do I need?

I would have PMed a member (bikerjosh for example) but the site is different now...?

So I'm planning on buying a set of TW triples to bore out to 35mm. And the RT 180 forks will have roughly 1.5 inch more height. Since I'm already pushing it higher with a Rox riser, I will need longer brake line and speedo cable but I'm not sure what to look for....maybe XT250 parts?

People speak highly of Tri-Z forks but I don't see any anywhere...any other suggestions for raising a TW ~2"?

Once I get this all sorted I'll be adding the 2.5" extended swing arm I've been sitting on. and likely making a spacer to raise it till I figure out a slightly stiffer rear spring. The stock is fine (only bottoms out on jumps over a 2') except with the added leverage of the swing arm I suspect I will want a slightly stiffer spring...maybe the white one from procycle?

Thoughts?
 

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I have seen the RT180 fork swap but saw no details on what is entailed for proper disc and caliper alignment. Dip into XT & TTR parts bins for cables and hoses.
Forum member Gerry built my 35mm Tri-Z fork/ Banshee shock/ Raptor spring(?) set-up and I really, really like it.
I have complete TTR front end from 36mm forks, triples, cables, disc, hose, master cylinder to brake lever courtesy of CJ7Pilot to be mated with another Banshee shock/Raptor spring combo for Betty Boop. Supposedly finite element analysis by others indicates even with the 36mm bore the point of failure should be buckling of fork tubes before fracturing of the bored out cast triples.
 

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Discussion Starter #3
Thanks Fred

Gerry did a great job on that build. I read is suspension thread over a few time as well.

I believe the RT rotor is the same size but the caliper mounts not compatible. I wonder if a bracket adapter might work to use the TW caliper.

Is the TTR triple TW compatible? That would be nice too to get a taller skinnier front tire.

I have a R6 mono shock that has one seized needle bearing..I'm hoping the rest is ok but I won't know till I mount it.
 

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Just payed for the TW triple tree. It's on!
Now I need to figure out how to bore them or who to pay. My guess would be to shim the gap to match the 33mm and bore it to 35mm. As far as tools....that's one hell of a mill!
You can use a long large tapered 34mm to 35mm reamer to do it. I got mine off ebay for like 45 bucks and then resold it for 65. You just need to create a little better starting ramp on the reamer with a bench grinder so you can get it started strait in the 33mm bore. You do need to lock a shim in (good) just like like you said...(to have the proper gap).. I used a hole hog drill on low RPM on the last two holes (got tired of twisting) but did the first two by hand.

Machine shops will hit you with a setup charge to build a jig to hold it so they can use a bar. Just put it in a vice and hog it out.

Better yet just lower a KTM and be done with it Ms.. TWBrapppsss.. :) LOL

35mm Reamer.JPG
 

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Thanks JJ

That's good to hear. I think I can do this...I don't think my wrist could handle sanding it out. Hole hog it is.

If I knew about the KTM freeride 250f I might have went that route when I could afford it. No regrets though I still love my Tdub...just needs a little tweaking.
Take your time and watch ebay, those reamers come up cheap often enough. Best wishes wit it :)
 

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Oh yea, the longer the better. The longer it is, the less resistance when cutting..(do to the reduced angle of cut).
 

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I'm not sure what type of bit you're referring to...

I would think try a step bit or scribe 1mm from the edge to find center then a forstner bit.
Sorry if i said "Bit" I mean REAMER. Also, if you use a hole hog, use a variable speed one in low gear at the lowest RPM. Not the model with a click-on / click-off switch.

Forstner is for wood.. no good. Step bit, no good...

Use A tapered hand reamer (or stepped reamer if you can find one but rare) (see pic for tapered): They are on ebay all the time.. Tapered finishes off to a parallel bore, no taper when done reaming.


35mm Reamer.JPG
 

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Hey Jeeper,

I am interested in reaming out some TW triples from 33mm to 36mm. Would you suggest doing that in several steps or do you think that it could be done with just one pass? I was thinking that maybe the top triple (aluminum) could be done in one pass, but I am not sure about the bottom triple which is cast iron. What type of surface finish would these reamers leave behind, and would it need to be further honed or polished?

Thanks,

Brian
 

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Hey Jeeper,

I am interested in reaming out some TW triples from 33mm to 36mm. Would you suggest doing that in several steps or do you think that it could be done with just one pass? I was thinking that maybe the top triple (aluminum) could be done in one pass, but I am not sure about the bottom triple which is cast iron. What type of surface finish would these reamers leave behind, and would it need to be further honed or polished?

Thanks,

Brian
Hey Brian,

I would go in a couple of passes if I had the reamers already on hand, but at 60-100 bucks i'd at least try the larger one first if you can get a real long tapered one.

That cast iron cut a lot easier than I thought it would, just tale it slow. I was lucky and had found a used 4 flute multi-step reamer. I should have kept it, it was great... NEW they are $$$$

It was a lot easier with the stepped reamer than when I did a friends with the tapered one, but even that was not really that hard. I did not use the chinese cheapey reamers though, no idea on the steel quality there.
 

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Brian, the finish was surprisingly good. Not mirror like but it would not grab a finger nail. You could see some waviness, more than acceptable. The tapered had a better finish that the stepped reamer.. (obviously)
 

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I'll share some of the cost with Brian if it helps further a future Wrench-n-Ride-n-Ream get together.
E-bay does have the reamers to go from 33 to 35 & 36mm but may have to go to Bulgaria for reasonable pricing.;)
This could be another reasonable fork swap to improve the TW's suspension since there are several donor sources.
I have a set of 36mm TTR225 forks with fresh seals and boots, just need to tear into bike to get TW forks for machining. Now that am back from Moab I have a few projects to complete.
 

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Discussion Starter #15
How tall are TTR forks axle to top? ~32.5" Anyone have a measurement on the XT? Now that I think about it more I might opt to go a bit bigger 2-3" At least with longer forks I can drop them down in the trees if they're a little tall.
 

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How tall are TTR forks axle to top? ~32.5" Anyone have a measurement on the XT? Now that I think about it more I might opt to go a bit bigger 2-3" At least with longer forks I can drop them down in the trees if they're a little tall.
My XT225 forks measure 32.5" from the top of the upper fork leg to the centerline of the axle, and 36" overall as shown below. These upper fork legs are 36mm in diameter.

IMG_1838[1].jpg
 
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