Crusty's 75th Annv PW #1590 build/mods adventure

[Crusty old shellback]

Got some more parts in today
Regulator with a 600 PSI gauge and hose.



300 PSI gauge to replace the 600 one .


No loss air chuck for filling.



Just need a couple of adapters and a on/off valve for the chuck.

 

[Crusty old shellback]

So did all of the machine work on the rest of the shocks. Installed the schrader valves with a dab of blue locktight. They are sitting under pressure now to see if they leak.
Ordered oil and rebuild kits from Summit racing. Should be here tomorrow.

 

[Crusty old shellback]

Got a package today .





So these look like Fox kits. They do have a lot more parts in them than the poly performance kit I had before. And they cost less.

 

[Crusty old shellback]

Got the last parts for my charging rig. Tested it out and it works.

Also put the 300 PSI gauge on a equalized the pressure at my altitude.

 

[Crusty old shellback]

So looking at the rebuild kit, id say it's a complete kit. Besides all the O rings, it comes with the following.
From top to bottom
1. Lock nut for the shock mount shaft.
2. Bushings for the top shock mount.
3. External Bumper for the shock shaft.
4. Bottom seal internal bumper.
5. Bottom seal bushing.
6. Bottom seal seal.



None of this was in the poly performance kit I had purchased

 

[Crusty old shellback]

Well started the shock rebuild today. Replaced seals, bushings and O rings. Bushing I had to knock and then press in the new one using a small vice. There was quite a few O rings left over. They should be for the remote resi, which I don't have
Next will be to set the IFP depth, fill with oil, seal up and pressureize the shocks.

 

[Crusty old shellback]

Shocks are done. Install tomorrow.



Some key notes from the process:
Seals are a pain to get out and put in. They are held in by a lip. Basically incased in the part.

I made a measuring stick to set the IFP depth. It's different for the front and rear shocks.



The shim/valve that goes on the bottom of the piston is different from all the other shim. There is a specific position it must go on the piston, otherwise it will not work. The shim is upside down so you can see the marks from where it has been on the piston.





A charging set up like I got works great for charging. The pressures are different between front and rear.

 

[Crusty old shellback]

Here was my procedure.
Schrader valve installed.
Install IFP.
As I pushed it in, I released pressure thru the schrader valve. I tried to get it with the IFP in its position and some residual pressure in the chamber, but not enough to push the IFP back up when I let go of the measuring stick.
Next i filled the shock about 3/4 full with fresh oil. Inserted the piston and shaft assembly. I then cycled it some to burp out any trapped air, being sure not to pull it up too far where it would come out of the oil.
I then pushed it in trying not to push the IFP in and build pressure on the back side.
Topped off the oil and put them n the bottom seal block and clip to hold it in. Installed dust cover.
Then pressurized the shock to the correct pressure. You will know everything is working if the shaft rises out of the shock till it bottoms out