Help rebuilding RockshoxJudy 95/96

I've a pair of Judy 95/96 that came on a bike built and sold by Chas Roberts. They are slightly unusual with a mish-mash of bits and were probably custom assembled by the shop in a bid to save weight. This would be consistent with many of the bikes other components, which were clearly selected for their light weight.

The lowers and brace were red DH (now repainted white), but the crown looks like an SL, and inside there's a Risse damper. The damper seems to be in good shape and the rod moves smoothly. Generally the forks are in remarkable condition, with no signs of excessive wear or deterioration to seals or other internals.

The elastomer stacks were slightly different lengths, seeing as how this was put together for a premium bike by a well regarded builder I can only assume there was good reason for this, my plan however is to replace them with steed springs, which I already purchased from SRP.

The problem is I never owned suspension forks before, let alone stripped and reassembled a pair, so I'm concerned about doing it right. As these are not OEM the collection of parts does not conform to any Rockshox owner manuals or videos covering tear downs and servicing that I found. I did the tear down without issue some months ago, but would really appreciate advice before attempting reassembly.

Things I'm concerned about.

1. Reason for the difference in length of elastomer stacks and potential impact on compatibility of springs.
   
2. Absence of elastomer 'skewers' as seen in vids showing disassembly of these forks.
   
3. Correct orientation of the Risse damper, and whether to consider sending it to the US for a service.
   
4. Other parts that may need replacing.
   
   

Any advice or guidance from anyone who has experience with these forks would be much appreciated.
The attached image was taken when I first started disassembly, I can post more pics of specific parts in required.

Cheers.

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I have no advice I'm afraid but wish you luck - love refurbishing and sorting out old stuff!

Things I'm concerned about.

Reason for the difference in length of elastomer stacks and potential impact on compatibility of springs.
Absence of elastomer 'skewers' as seen in vids showing disassembly of these forks.
Correct orientation of the Risse damper, and whether to consider sending it to the US for a service.
Other parts that may need replacing.

Is the difference in length of elastomer stack anything to do with the damper? Like it takes up some space in the leg?

I had a Judy XC a couple years ago that I tore into and serviced and I don't think it had elastomer skewers either. I think I remember reading about a design revision at some point that either added or removed the skewer?

Is it possible to fit the damper in anything other than one orientation? Doesn't it have to fit up inside the leg and will only go one way around? I think the original plastic dampers were orientated with their open end down, just to make sure they dumped all their oil out as soon as possible?

Thanks, same here!

Is the difference in length of elastomer stack anything to do with the damper? Like it takes up some space in the leg?

Cheers for the response. I was thinking along the same lines, although the shorter stack was in the other leg.

I had a Judy XC a couple years ago that I tore into and serviced and I don't think it had elastomer skewers either. I think I remember reading about a design revision at some point that either added or removed the skewer?

This is possible, I only asked because the vids I saw that had springs reused the skewers, but I imagine they will fit and work without them.

Is it possible to fit the damper in anything other than one orientation? Doesn't it have to fit up inside the leg and will only go one way around? I think the original plastic dampers were orientated with their open end down, just to make sure they dumped all their oil out as soon as possible?

Again I think you're right, I just forgot which way they came out, and now I look at it there is no physical difference between each end externally.

Cheers for the response. I was thinking along the same lines, although the shorter stack was in the other leg.

Mmmm strange.

I was going o suggest it might be that the elastomers had degraded, one side more than tother but I see there's actually fewer elastomers in the stack.

I'd guess that while this era of fork is now becoming somewhat desirable again, this hasn't always been the case and there'll have been a while that spares availability was a bit shit so might just be that they've been kept going with what could be found.