What oil in the forks will produce a smooth ride ?

No got a bit mixed up with the BSA which are 5/16, so just go for 3/8" ID and 15/32 OD
  • Recommended tolerances:
    - Housing - min/max: 0.4684/0.4691inch
    - Shaft - min/max: 0.3731/0.3740inch
  • Bearing size when fitted:
    - Bore - min/max: 0.3742/0.3769inch
I like the teflon coated bushing but the bored out alum cap would be about .012" thin on the flats - weak.
 
No got a bit mixed up with the BSA which are 5/16, so just go for 3/8" ID and 15/32 OD

I like the teflon coated bushing but the bored out alum cap would be about .012" thin on the flats - weak.
But on the RGM the flat does not extend downwards very far so the bottom of the hole is full thickness and the bush has a steel wall so is stronger than the alloy it replaces.
 
But on the RGM the flat does not extend downwards very far so the bottom of the hole is full thickness and the bush has a steel wall so is stronger than the alloy it replaces.
There's a way the strengthen that area. I'll make up a prototype and test if for a couple months.
 
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