Marzocchi DJ fork clamp nightmare! Help pls!!!

gravelrash6

Hi everyone, please excuse any newbie mistakes/faux pas...

So...after spending 2 hours cleaning my Kona Cowan, adjusting gears and retightening a crank arm that was about to fall off, I got to the front hub. Cleaned, regreased and reassembled I tightened the last of the weird clamp bolts on my 2004 Dirt Jumper forks and...snap. I know I'm an idiot and need to buy a torque wrench.


Anyway, I can't find a replacement nut/screw combination anywhere on the Internet (theyre discontinued whenever I've found a link). Tried everywhere. I cant seem to upload a picture of them but they have a rounded T-bar piece at one end with a bolt thread and a rounded 6mm allen nut at the other.

I was wondering if anyone had one of these lying around in their garage doing nothing that I could buy from you? You'd save me having to get rid of a perfectly good fork and buy a new one...which unfortunately I can't at the moment.

If you can help me here I'd be extremely grateful

nicklouse

read the how to in the FAQs for uploading pictures or just add it as an attachment.

also a clue as to which DJ forks they are would help.

and try a machine shop for having some made. if contacting your local Marzocchi deal does not result in the parts being sent by Windwave.

gravelrash6

Of course. It would help... :oops:

It's a 2004 Marzocchi DJ (1 I believe) QR20 fork.

Here's the fork... [img]<a%20href="http://www.flickr.com/photos/88967077@N07/8108277169/&quot; title=&quot;Marz 2004 DJ axle clamp bolt by battycrease4000, on Flickr&quot;&gt;&lt;img src=&quot;http://farm9.staticflickr.com/8469/8108277169_66731592e2.jpg&quot; width=&quot;269&quot; height=&quot;360&quot; alt=&quot;Marz 2004 DJ axle clamp bolt&quot;&gt;&lt;/a&gt;[/img]

...and here's the little wotsit I'm looking for...[img]<a%20href="http://www.flickr.com/photos/88967077@N07/8108279395/&quot; title=&quot;QR20 clamp bolts by battycrease4000, on Flickr&quot;&gt;&lt;img src=&quot;http://farm9.staticflickr.com/8463/8108279395_27e5b8c150.jpg&quot; width=&quot;500&quot; height=&quot;316&quot; alt=&quot;QR20 clamp bolts&quot;&gt;&lt;/a&gt;[/img]

If you can help I'd be very very grateful

gravelrash6

Maybe this'll work?!

cobba

Is this what you want to do below ?

You need to click on "Img" and insert the following link:
http://farm9.staticflickr.com/8467/8108 ... a66b_z.jpg
then you do the same for this link:
http://farm9.staticflickr.com/8469/8108 ... 1592e2.jpg
and also this link:
http://farm9.staticflickr.com/8467/8108 ... a66b_z.jpg

nicklouse

as you can see the one on the left has been bodged. the one on the right is original.

normally it is only the bar that fails.

if you have also stripped the cross bar then a bolt will be needed as per the left one.

if not a bit of threaded bar or get some bar threaded.

easy fix.

gravelrash6

Thank you cobba and nicklouse....much appreciated!

Mine has sheared level with where it meets the 'rounded nut' (top of pics). I guess I'd have to drill out both the nut (with the broken bolt section inside) and the bar section (with the remains of the threaded bolt stll fixed (how by the way? Weld?).

Am I right on this guys?

Cheers

nicklouse

should just unscrew as there is nothing holding it in place.

but again Pictures of what you have.

as that is all we have to go on.

so the images you used were not your actual parts? what is the point in using them then?

gravelrash6

[img]http://farm9.staticflickr.com/8469/8108 ... 1592e2.jpg[/img][img][/img]http://farm9.staticflickr.com/8467/8108 ... a66b_z.jpg

Sorry...hope I've nailed it now (though I still can't see pics in preview )....

Anyway, the bike's mine.

Pictures of fork lower/brake disc not mine (from a early 66 or 888 I believe but identical to mine).

Picture of two T-bar bolts and nuts found on web. One on right (original) is what I have but snapped.

You're dead right though. Have unscrewed the threaded rod by clamping in vice. Now need to find a threaded rod with same thread pattern.

In the meantime...if anyone has an original gathering dust that I could buy from them I might have more faith in it's strength than something I've bodged.

cooldad

That's because you haven't posted pics. Try again. One at a time. You have two 'open pic' thingies on the first attempt and two 'close pic' thingies on the second one.

gravelrash6

Ah ha!...thanks for your patience cooldad.... :oops:

The bike...


The fork lower/axle clamp...


And the problem little thingy (original on the right. That's what I have but in two pieces!)...



As I was failing to say...its snapped...beyond repair tbh considering my limited engineering skills (though I've discovered that its a M5 thread size for what it's worth). If anyone has any tips or a spare to sell me please let me know. Many thanks

cooldad

Am I seeing double?

gravelrash6

Err..not sure what you mean. I'm a total newbie, have I made a mistake? If so can you tell me what it is please, just thought someone might be able to help thats all.

cooldad

nicklouse wrote:

should just unscrew as there is nothing holding it in place.

but again Pictures of what you have.

as that is all we have to go on.

so the images you used were not your actual parts? what is the point in using them then?

An answer to this. The pics are the same.

gravelrash6

Ok. So I surmise that you can't help with the problem I have regarding the actual part. Thank you for your comments in the meantime.

cooldad

Can't you just bodge one with a threaded rod or cut down bolt.
Or Windwave are UK agents.

nicklouse

so have we seen the broken part yet?

gravelrash6

Here we go....

gravelrash6

Thnaks cooldad...I'll email Windwave too.

cooldad

nicklouse wrote:

as you can see the one on the left has been bodged. the one on the right is original.

normally it is only the bar that fails.

if you have also stripped the cross bar then a bolt will be needed as per the left one.

if not a bit of threaded bar or get some bar threaded.

easy fix.

This