April 25Apr 25 I broke the bottom of the lower fork on my Montesa rebuild. ChatGPT told me to hammer down....the forks come up.... I should have realized but didn't. I heard about welding but I think here in Alberta, CA it would be very expensive and no warranty or guarantee. I see exact parts on ebay in the US that look almost new. They look too good to be true but I assume I could rebuild the forks with new seals... Or is it best to try to get an entire fork - upper and lower? The old shocks seemed to be functional 25 years later. Any recommendations would be great.
April 26Apr 26 The lower fork legs wear oval in the bore after years of use depending on how often the oil was changed, measure the bore in the lower legs for true to round before investing in a weld repair. Very few will have the tech to weld that material efficiently.
April 26Apr 26 @ FHG Sounds familiar , One listens to a machine pretending to be a person , you then take its advice , you believe what it tells you and then everything gets broken , affects you personally and costs you money. Edited April 26Apr 26 by Tr1AL
April 29Apr 29 If the bores are oval, you can have them machined to take modern Teflon coated bushings, or bronze. But, it would be much easier to find a replacement.
April 29Apr 29 55 minutes ago, mcman56 said: If the bores are oval, you can have them machined to take modern Teflon coated bushings, or bronze. But, it would be much easier to find a replacement. That would be affordable if you are the guy doing the machine work and you have all the equipment already.
April 29Apr 29 Author On 4/26/2026 at 7:55 AM, lemur said: The lower fork legs wear oval in the bore after years of use depending on how often the oil was changed, measure the bore in the lower legs for true to round before investing in a weld repair. Very few will have the tech to weld that material efficiently. Thanks ALL - I ordered the lower leg on EBay - I can always repair it later if needed. $115 seems safe and it looks like new, just like my current forks. All parts ordered - seat from Spain - can't wait to put it all back togegether.
May 2May 2 On 4/29/2026 at 7:16 AM, FHG said: Thanks ALL - I ordered the lower leg on EBay - I can always repair it later if needed. $115 seems safe and it looks like new, just like my current forks. All parts ordered - seat from Spain - can't wait to put it all back togegether. Include a photo when you’ve got it back together. Best of luck!
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