Fork cap removal problems

[Slakewell]

 I have some 77 YZ forks and I can't get the caps out, I have done the normal things, made sure the forks are well thou the clamps so the clamps are not binding the caps, heat gun etc , I just used the correct size impact 8 sided socket with a stiff wack from the rubber mallet and crushed the hex. Apart from machining them out does anyone have an idea?

[frostype400]

I have used when my impact driver didn't get them a normal ratchet and a bit of pipe to get a heap of leverage on the ratchet.

[monaro308]

Try a heat gun on the tube and try tightening them up first and then back them off...if you can.

[ba-02-xr]

Common Mick take of your skirt & have a go .

[Slakewell]

As you would know John most folks bring this type of problem to me , It's normally not my own stuff, I have never seen aluminum stuck in steel as good as this.
I will probably just bore them out .25 over the thread size and then just pull out with left overs.

[SLAWESY]

Slakewell, Try using a six sided socket. It seems to give a closer and more secure fit. You may have to smack the socket on to the cap if the edges have caved in a bit. (you can normally pick one up in a hardware shop). Also make sure that you have completely loosened the top triple clamp bolts. Has worked for me when the caps have been attacked by some heavy handed mechanic.

[lukeb1961]

I had a '78 PE/RM fork like that about 5 years ago.. one cap undid with a gentle push but the other...
After four nights of failure, ended up putting the entire front-end into a hefty vice, then getting some plumbers stilsons onto the cap head - gave it a good wallop with a wooden mallet for good measure - AND used a three foot bar on the Stilsons...  It promptly moved 

Sometimes excess force is barely enough.

[chrisdespo]

Get a shinano 3/4 drive rattle gun not much wont yield to one of these....

[Slakewell]

I have used a six sided impact socket and bar , It has just crushed the nut and turned into mush. Now looking for 38mm Yamaha for caps