repairing fork leg inner

[evo550]

Just rebuilt a set of forks and it seens a dent on the outside of one of the legs is causing the fork tube to bind up one it's way through the stroke.
Can the internal binding be repaired,or am I up for a new leg?
In Brissy, if anyone knows who might be able to help.
Thanks

[matcho mick]

how about machining up a "dolly"(with a curved lead) to fork bottoms id,threaded/welded shaft attached,warm the fork bottom & "send" up/down the dolly to see if it can ease the indentation outwards?? ,worth a shot!,

[flattracker]

I have been thinking about a fix for this for a couple of days now. If the dent isn't too bad you could use a brake cylinder hone to remove the high spot. remember lots of kero when you hone ally as it stops the metal build up on the hone stones. matcho micks' idea could work also ,but be careful with heat as you don't want to aneal the lower leg too much and soften the ally.

[JohnnyO]

I have heard of people honing them to remove the high spot but you'd need a pretty long hone or an attatchment if it's down near the bottom of the leg.