Any question answered...

If you are able to glue it back together, its shape looks like it would lend itself to being used as a former for lost-wax casting. Last time I looked there were a couple of people offering this service in the jeweller's workshops in Clerkenwell Close. They usually cast in silver (not as spendy as you might think) or brass. Might work out cheaper than asking a metal shop to fabricate a one-off.

For a man of considerable engineering knowledge you surprise me!

@villa-ru Lasermaster or Laser24 (there are loads more but that’s who I generally use) could cut you one for £20 or £30, depending on how generous they’re being with their minimum order.

You might be able to send them a hand drawn sketch, but if you PM me a dimensioned drawing I’ll make a DXF (digital line drawing they work from) for you.

If you size the screw holes right (just smaller than the head of a countersunk screw) you probably won’t have to countersink them.

Thanks all - that's really helpful.
@dbr - I'll measure it up properly and pm you.

Cheers!

TBH I could probably just make it by hand in exchange for a six pack. You in London?

you surprise me!

I'd rather people were pleasantly surprised by the price quoted in real life than the other way around.

There are shops who will do stuff for surprisingly small fees, but first you have to find them.

"get a replica made" and "make a functional replacement from CAD files prepared for nothing by a friend" are two different things 🙂

Fair. Just surprised laser cutting was omitted from your answer.

surprised laser cutting was omitted from your answer

It was included in "several ways to cut that out from sheet", which covers laser, waterjet, plasma jet, flame cutting, fretsawing, wire EDM and milling/routing. Technically, it includes die punching too, but I didn't think it was likely to be the best method for a one-off 🙂

Read about wire EDM years ago, would love to see it in person.

Just YouTubed it. Not so exciting really.

Not so exciting

There's nothing to watch when it's in progress, but the capabilities are pretty useful

Is wire EDM the same as Spark Erosion?

Spark erosion is a colloquial term for the whole field of electric discharge machining, wire EDM is a particular method. The other main method is sinker EDM.

Ta, gbj.

How thick is it? Looks like it'd be pretty easy to make from aluminium with a hacksaw, files and a milling machine.

a hacksaw, files and a milling machine.

A mill is more than is needed, you just need a drill to make the screw holes and at least one piercing as a starter hole for the oblong cutout.

Yes - Streatham. Would be very happy to travel though and sort out six pack payment!

@Brommers - have some general DIY skills, but know that replicating something like this will be far better done by someone else.

Well, depending on the thickness and the degree of urgency involved, I could have a stab at replicating it in aluminium. Depends on the thickness - I have a selection of alloy plate, but not every possible thickness. Although I can mill it down if I've got something close.

Are you just a bored lawyer milling about?

I'll get me hat.

I'd love the luxury of being bored. Got a hearing in the High Court on Monday morning that I was made aware of on Friday morning.

But have milling machine, will do milling.

Fork id please

1 Attachment

I'd say rock shox Judy XC

I concur, a rockshox Judy

Bolts on the crown look like old Rockshox Judys? Looks also like a Rockshox decal below the brake bosses.

Ah. Beaten waiting for wifi to reconnect!

Might toothpaste and a rag be helpful in this case?

Sorry for late reply but this did the job PERFECTLY. Really surprised that rubbing it with a cloth did nothing at all, but adding a tiny bit of toothpaste and the stuff came off right away, like magic.

Soooo relieved! Thanks everyone!

Was it sensitive or whitening?

👍 It’s a mild abrasive, works for stuff like that.