1955 Model D 150 - Front forks installation

[Big Al]

I am about to fit the front forks back into the frame tube.
The inverted upper cone (99096106), which sits above the ball race and below a new chrome protection cap, seems an extremely tight fit inside the frame tube. It will not just push in.
Is this correct, and if so, what is the best way of drawing the forks up inside the frame tube?
Should I thoroughly clean the inside of the frame tube first with emery paper or similar perhaps?

[Big Al]

The cone (99096106) is called the "Lower steering ballrace upper cone" in my parts book, but it's the one that goes at the bottom of the frame tube!

[jbcollier]

Which part number in the diagram below are you talking about?

https://scooterhelp.com/manuals/LD_D.15 ... page41.jpg

[Big Al]

Number 79 John (the inverted cone under 78 the chrome ring).

There is probably paint inside the frame tube which would not help. The painter seemed to spray everything, including some of the threads on the parts, which was not very sensible.

Alan

[jbcollier]

Carefully use a razor to clean the paint out of the bore AND off the end of the frame's fork tube, top and bottom. The upper and lower bearing cups should be a press fit into the bores. Very careful work with a hammer and a block of hardwood can do the job. I prefer to use washers, nuts and a long piece of large threaded rod. It allows more control. Both cups need to be fully seated against the ends of the tube.

[Big Al]

Thanks John. I will do as you suggest.

[Big Al]

I managed to get the lower cone back in yesterday. I had put it in the freezer for a few hours, in the hope that it would contract a bit!
I had also scraped all the new paint out of the frame tube. The cone then tapped in fairly easily, and I was able to get the forks back in, bolted down securely and swinging freely.

[jbcollier]

Excellent!