Since you are trying to improve on the Matris cartridge kit, what cartridges are you planning on using? I have a couple of sets of 851 41.7’s that I would like to use but I want them to work more like modern forks.

Thx
John

Hang in there Johnny and stay tuned. This thread is documenting what I did and probably not the best way. Parts I used are a combination from various front ends. The machining of the bearing and seal housing done from the end. The bottom were the cartridge would sit is not originally machined so that required making a custom cutter to go down the hole to spot face.

Very interesting topic
Thank you for sharing.
Filippo

Next to adapt left leg for threaded bushing to upgrade to 20mm axle. Spun up a Ti axle to fit.

adapting the old rebound housing to a proper compression adjuster. A splitter plate added to the bottom of the cartridge. Other Leg would be fixed orphic.

Some pretty impressive stuff going on here. Where did you get your training?
Flattop

Training? I just learn from many mistakes . Next to adapt old GSXR fork caps to fit the tubes. Rethread and adding O ring groove. I have a pile of parts from doing suspension work so I just pick through and find some thing that looks right and adapt it.

Reworked Hyabusa catridge bodies and rebound valves. Reworked 25 mm gold valves for compression side. Ohlins springs with custom made top out springs. Upper bushings are sourced from BMW.... very expensive but that magic 41.7 ID. Those with eagle eyes will spot the relieving of the tube OD were its not used to allow more oil flow. Final overall length 750mm. Was very happy after all this machining to get approximately 4 mm of stiction variation. That's equal to most fancy front ends!
-Cranky-

Hi my friend, I'll show you how I mounted a Showa pump on a 38 M1r

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