I'm rebuilding my '46 Chief fork and punched out the needle bearings and plan to replace with bushings. Have inspected the shackle bolt ends and they look good...no galling or rust. I'm using new "O" rings to seal the bushing/shackle ends.
A couple of questions. How deep should I press the bushings into the fork components? They wouldn't seem to work if flush and need to be countersunk a bit to allow the "O"ring to seal properly. I plan to make a brass pilot on my lathe to ensure proper alignment and equal depth for all bushings when they go on the press. I have also drilled out zerk fittings in the fork/triple tree to get better lubrication.
The other question is how tight is tight enough when it comes to snugging up the end nuts on the shackle bolts. There are knurled washers which I suspect were used to sense tightness at each shackle end. This is my first girder fork, having worked on several earlier leaf spring forks.
Thanks in advance.