Everything went smoothly until I got to Roxy's fork plate. Even with all the bolts removed, it wouldn't budge from off the fork, not even the slightest give. I gave it a couple whacks with the rubber mallet, and still nothing. It really seemed frozen in place, which seemed surprising given that nothing else was frozen or stuck. I'm guessing corrosion on the bottom of the plate had frozen it to the top of the fork tube.
It didn't seem like the right time to apply any extra force. I'm going to sleep on it and see if anyone has advice.
But since all the hardware was out, I took the opportunity to sand it down with 150 grit sandpaper to get the corrosion and grime off. It cleaned up nicely, but it would have been much nicer painted black, since that really lets the chrome bolts pop out.
Re-assembly went pretty well, too. I used the old torque wrench to tighten the top fork bolts to 29 ft-lbs. The top steering bolt was supposed to be tightened to 58 ft-lbs, but I would need a 29mm socket to do that! Also, I tried using the torque wrench to tighten the handlebar mounting bolts to 7 ft-lbs, but I think that's below it's limit as it didn't seem to ever click.
Also gave the handlebar mounts a good sanding and then some Autosol polish.
Before...
The fork plate before sanding.
The bottom mounts were slightly different. Roxy on the left, Viola on the right.
Everything going back on. New fork and steering head bolts.
All done. Looks clean, but still not as good as if it was black. Also need to clean up the handlebars as the rust now stands out against the clean metal behind it.
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