Today’s work involved what may be considered “ruining” perfectly good, brand new forks. This is for my kid though and as you can see from the pictures, he is still barely y’all enough to mount this thing.
I read the wiki for shortening EBRs. Looking at how much I needed to drop the front end, I had to go pretty far with it.
These started off with about 3.5” of travel. I decided that he could do with 2” of travel since he weighs 60lbs and will be on paved surfaces with this thing. I know this would be bottoming out all the time if I was on it. Meh. That’s the price to play this one.
Anyhow, I unscrewed the top and bottom tubes, removed the spring and punched out the pin holding the spring-retainer-plastic-thingy in the upper tube.
Stuffed paper towel into both tubes far enough to block contaminates from getting in the grease while cutting and drilling. I cut 3” from the top and bottom tube.
At this point, if you moved the spring-retainer-plastic-thingy up 3” and put it all back together, you would be 3” lower with the same travel. The upper and lower plastic bushings (go on the outside of upper tube) need to be measured and holes drilled for them to be inside the lower tube for the full suspension travel.
To get that extra 1.25” of drop, I cut 1.25” of spring off.
The boot sits flush against the fork brace mounts and the lip inside the boot is engaged on the upper rim of the bottom tube. No more than 3” can be removed without messing that part up.
I ended up with forks that are 4.25” shorter and have 2” of travel before the boots hit the lower triple tree. We could shave the boot down some, but I think we’ll see how it goes.
Pics show the bike sitting on some old MB rims. Just to get a feel for ride height. OD is about 20”. I still haven’t bought rims because I’m waiting on the hub motor to get here. I know it is 36 spoke. There should be plenty of 16-17” rims that can work with it.