Reading this I was thinking why not ride at a gutter with top cap removed..... then realise maybe dampner off for rebuild so fork no ride. So no spring shooty outty.Had a spare fork...a new Fox 38...didn't really love it so figured fitting a Smashpot would be a great idea as I had a few springs lying around that would suit from previous builds with Vorsprung. Built it up with a 50lb spring at 170mm travel and put it on the Titan for a ride.
First impressions were the usual small chatter delete but the mid stroke felt super stout and on a longer run I got hand pain and I had only used about 70% travel...I was like WTF.
I figured I was getting old and less aggressive and needed a softer spring and blamed the damper on the harshness...stupid Fox.
I found a 45lb spring on ebay...bought it.
Pulled the damper and sent it to Shockcraft to try his unharsh tune (I've been curious about Dougal's work for a while anyway).
Last night I thought I would be pro-active and pull the spring in preparation for the lighter one turning up. Long story short...that fucking spring was not coming out.
With the 38 fork a clear plastic sleeve is inserted into the stanchion and then the spring/smashpot assembly slide inside of this. I had reused a spring that had previously been in a Fox 36 so this meant it has two layers of heat shrink on it to help reduce noise. This extra heat shrink had created enough of an increase in outside diameter that when the fork was assembled and ridden the bond between the spring/heat shrink/plastic sleeve/stanchion wall had become one and no amount of pulling was going to break it free. I ended up with the CSU removed with the spring still in there, clamping a spring end in a vice and having to unscrew the CSU from the spring.
The binding spring explains the mid stroke stoutness, the harshness and why I wasn't using the travel appropriately so I probably didn't need a softer spring or a goddam damper tune.