Fox fork lower leg removal tool

thingiverse

**Update - 8 July 2019:** * I eliminated the extra step of using a thread, so I removed it. Without this extra step, the grip texture is also unnecessary, so I got rid of that too. I simplified the markings to just show 10mm or 14mm instead of listing the forks that each can be used on. * I realized when working on a fork, I still tend to just use the socket on the fixing nut to loosen the shaft from the fork lowers instead of this tool. I'll leave this here if anyone is interested but I've found that even though I have these available, I don't find them all that useful when using the socket I already have in my hand is just as easy and effective. When servicing Fox suspension forks, you need to pull the lowers off of the stanchions. This can be done several ways. The way I've been doing it for years is by backing off the holding nut, then using a hammer on the socket on the holding nut to loosen the shaft from the lowers. This works fine, which is why I've been doing that for years. (Some folks hammer directly on the shaft which is a bad idea.) I recently saw that Fox makes tools specifically for this purpose. They're not cheap and they're a single-purpose tool, so I'm not likely to buy one. I could really only see it being useful for a shop that does a bunch of fork service. If you're curious, here are two online retailers which carry these tools: Universal and Worldwide. Since the design is really simple, I thought it would also be really simple to replicate in a 3D printed part, so here it is. There are three variations posted: * Short version for the air spring side on all forks as well as the damper side on 32mm forks. This uses an M8x1 thread. * Short version for the damper side of 34/36/40mm forks - these use an M10x1mm thread. * Long version for both sides of the 32 Step Cast fork which sinks the ends of the air spring and damper shafts about 110mm into the body of the fork - this explains the really long shaft on the Fox tools. All of the tools are marked on the end with their size. How to use them: 1. Check out http://ridefox.com/ for procedures on your particular fork. 2. Unscrew and remove the retaining nuts from both sides. 3. Thread the appropriate tool onto the end of a shaft. 4. Hit the end with a hammer or mallet until it breaks free. 5. Unthread and you'll now be able to remove the lowers. This is still a work in progress. I've tested fit on my Fox 34 and it looked pretty good, but haven't actually used this in servicing a fork yet. I have printed out a set that I've given to two friends who are bike mechanics in the interest of testing. In case you're wondering, the duck in the photo is my Rubber ducky valve stem cap which I made around the same time.