I read on here a week or so ago that you could use EG/DC forks as drop forks. So I bought a set from the junkyard and installed them yesterday. Here is how you can do it for yourself.
You want to go from this:
You gain a good 3/4" of travel (maybe more) with this mod which is much needed on a lowered car.
This little project took me 4 hours. But I was moving slow. After I figured it out I did the 2nd side in about 30 min.
1) First go buy some forks. Mine were off an EG because thats what I could find. The EK ones looked the same but I didnt want to take any chances. Mine were $20 at the junkyard.
EF fork on left EG fork on right:
See, they are a little different shape but it happens. They are the same height and the EG ones have a bigger inside diameter. The EF/DA forks have an ID of 1.502" and the EG ones were 1.650".
Bigger dia of the EG fork on the right:
Next you have to measure the dia of the brake line bracket (where the fork slips over). Mine happened to be 1.71". But they do come in different sizes. My stock teg ones were around 1.6" and the stock EF ones were about 1.8". This determines how much you have to “bore” out the forks.
Now its grinding time. I used our little air die grinder with a stone bit. I tried a bunch of different bits like drum sanders, and different gnarly looking metal bits. None worked except for the stone bit. If you have a dremel with a little stone bit this will take a LONG time.
I clamped the fork in the vice and ground the top 3/4" of the inside diameter to about 1.71". I measured the ID with a caliper periodically and test fit occasionally. Grinding takes a while because the forks are very hard.
3) The spacer:
The fork is only clamping to the shock with the top 3/4" and I didnt want anything wobbling around so I made a little spacer. Now the bottom of the clamp has someting to grab onto. I took a piece of 1/16" aluminum that was 4.5" long and 3/4" wide and bent it around one of my old stock shocks.
It slides between the fork and the shock like so:
4) The bolt:
I didnt want to viod my shocks’ warranty so I wasnt about to put a little divit (sp) on the shock. Instead I ground the bolt down. I put the bolt in the fork to where it starts to get tight and, with the die grinder, made the bolt the same shape as the inside of the fork. Then I took the bolt out and made it the same shape all the way around with the bench grinder.
Put the spacer on the shock. Then put the fork on the LCA (first) and connect the shock to the fork. You have to rotate the shock about 2 degrees from its original position because of the clearance between the fork and the brake line brackets. Tighten the bolts and you have more travel. Easy, eh?
If you were greedy you could probably get an inch or more out of this mod by taking .25" or more off the top of the fork and sliding it up on the shock more, but i’m not going to try it.
If you have any questions comments or corrections let me know. Ogle6@hotmail.com