HydraGlide Lower Leg Fit-Up

[billpedalino]

While fitting up my hydraglide folk assembly for my 1953, a problem arose that I haven't seen before.
With the fork tubs fully assembled and placed into the upper and lower fork brackets, when sliding on the lower legs, the right leg sits higher than the left leg - by a LOT. The difference is a gap of almost 3/8" between the upper axle saddle and the fat circumference of the axle on the right side. So the right leg sits high, or the left leg sits low when installed onto the fork tube assemblies.
As far as I can tell, I believe that I've checked everything that comes to mind such as the fork tube lengths, the parallel elevations of the bottom edges of the installed fork tubes, the parallel elevations at the bottoms of the slide-on lower bushings (46121-48), and the locked-in fit of the fork tube assembly in the upper bracket ((56121-48).
Given the above, i appears that the problem is in one of the lower legs. I thought that somewhere along the way, maybe someone 'customized' something and machined the inside of one of the legs. However, when checking the depth to which the lower busing sits against the inside, lower base of the legs, both measurements are the same at approximately 13-3/4" to the top of the legs. Also, the protruding thread length of the attachment studs at the bottoms of the lower legs are almost identical. Everything SHOULD fit - and yet there is a 3/8" gap between the axle and the right side lower leg axle saddle.
All the parts are OEM, although I acquired both lower legs separately years ago, and i don't know their history. But according to the parts book all panhead fork tubes (45950-48) should be the same as well as the lower legs (45800-48/50 and 45805-48/50) with the -48 legs being painted black in 1949 only.
This one defies geometric logic and really has me scratching my head. Has anyone had similar experience or any suggestions?

[Saddletramp]

Bill,
I'm installing my lower legs today after I shim the damper valves. I'm doing the install right out of the panhead service manual with the tubes inverted on a steel pipe in the vise. I'm glad I decided to do it that way because I found a larger than .004 gap between the damper tube lower bushing and the clip holding the damper into the tube. I'm talking thousandths and not like 3/8's though.

Once my clearance is correct I will install the legs again inverted onto the tubes and lock them down. At that point I will measure them to check for the same length of the assemblies to avoid a surprise like you have. Then install them into the fork brackets mounted on the frame.


I can't think offhand of anything that would cause a difference like you have. You may be right about the one leg you replaced. Perhaps a bushing has shifted inside the leg or something.

James

Edit: I'm sure you have checked the leg and also checked that one of your damper valves isn't binding inside the tube.

[billpedalino]

After doing more research I notice that there were different lower legs ('sliders') for the adjustable fork models (Left: 45794-50/ 45793-50). I would assume that these might have a slightly longer axle distance than the fixed fork models? If so, then I may have a left slider intended for an adjustable fork front end. However, I have virtually no experience with adjustable hydraglide forks
Can anyone advise as to whether or not the adjustable sliders had a slightly longer axle distance (about 3/8" or so) that the regular slider (45799-50)? This would definitively resolve my confusion, although place me back in the market for a standard left lower leg.
Thank you al for enduring my diatribe!

[Rubone]

After doing more research I notice that there were different lower legs ('sliders') for the adjustable fork models (Left: 45794-50/ 45793-50). I would assume that these might have a slightly longer axle distance than the fixed fork models? If so, then I may have a left slider intended for an adjustable fork front end. However, I have virtually no experience with adjustable hydraglide forks
Can anyone advise as to whether or not the adjustable sliders had a slightly longer axle distance (about 3/8" or so) that the regular slider (45799-50)? This would definitively resolve my confusion, although place me back in the market for a standard left lower leg.
Thank you al for enduring my diatribe!

Bad assumption. The numbers you give are just for a right side leg assembly or a left side leg assembly and the only difference from regular forks are the top caps, the reason they are designated for adjustable forks..
All lower slider dimensions for Hydra-Glide forks are the same until the Showa fork. All interchange. The only differences are the finish (black or polished) and the odd left side Servi-Car slider machined for the tow bar bracket. All interchange with no issues.

[billpedalino]

Bad assumption. The numbers you give are just for a right side leg assembly or a left side leg assembly and the only difference from regular forks are the top caps, the reason they are designated for adjustable forks..
All lower slider dimensions for Hydra-Glide forks are the same until the Showa fork. All interchange. The only differences are the finish (black or polished) and the odd left side Servi-Car slider machined for the tow bar bracket. All interchange with no issues.

Thank you for that Robbie - It certainly appears that I have an oddball right or left slider.....With both fork tubes and dampener assemblies installed. the fork tube bottom edges and the dampener bottoms are exactly parallel. When you slide the lower legs on, the right side sits higher that the left side at the axle saddle. Very odd...

[Rubone]

Aftermarket slider? Damper parts identical from side to side? Machined depth identical from tube to tube? Tophat missing on one side? Something is screwy because if it is all factory parts there are no variations, not a like a Sportster with high and low road clearance parts.