Wonderful, probably my favourite bike ever, but I'd suggest a Marzocchi Z2 instead. The 100 mm of the Z1 would throw the geometry off completely, the Z2 is slightly lighter, and it still has wonderful damping, with its open bath cartridge. First Generation Marzocchi have a replaceable steerer, and you can easily fit a 1" unit.
Prodigal Son
Senior Retro Guru
A well tuned mag21 would work nicely.
No2ndPrize
Merlin Fan
Apart from the geometry issue, the Z1 is comparable heavy.
I had exactly this orange Z1 model as a temporary solution in my 96' Litespeed Ocoee frame. The Ti frame is quite lightweight (similar to yours) and the heavy fork makes the bike unbalanced and top-heavy. I can't recommend this.
I'm not saying you should put only wheight weenie stuff on it, but the Z1 is exactly the opposite.
I had exactly this orange Z1 model as a temporary solution in my 96' Litespeed Ocoee frame. The Ti frame is quite lightweight (similar to yours) and the heavy fork makes the bike unbalanced and top-heavy. I can't recommend this.
I'm not saying you should put only wheight weenie stuff on it, but the Z1 is exactly the opposite.
Merlin partnered with Pace around this time, used their forks on a few show bikes and their suspender frame. A good RC35 is the perfect match and can be easily serviced by a few people on here with parts relatively easily available
Bytesex
Dirt Disciple
Looks like the Z1 is more than a pound heavier than the Judy! I‘ll do a post comparing weights, once the Z2 is here.
Bytesex
Dirt Disciple
A good looking fork for sure! Had a quick look at it before. A perfect match based on style, but using elastomers?!
Bytesex
Dirt Disciple
Thanks to everyone who commented on potential forks for this bike. I am now going for a Marzocchi Z2 BAM
Here‘s a little comparison by weight:
RockShox Judy XC with steel springs, 1600 gr — Marzocchi Z2 BAM, 1680 gr -- Marzocchi Z1, 2100 gr
I haven‘t opened the Z1 and Z2 yet and just got them so I don‘t know how much oil is in there. Should have an effect on the weight. Marzocchi has listed the Z1 with 1760 gr in their ‘97 catalogue. This must be without oil which would be pretty funny. In the ‘98 catalogue they stopped listing weights altogether.
In any case, I will be servicing/rebuilding both Bombers that I got. Will be riding the Z2 and sell the Z1.
Looks like the Z2‘s color is also the better fit with the Merlin. And I do love Italian colors and the Italian mountains!!
Here‘s a little comparison by weight:
RockShox Judy XC with steel springs, 1600 gr — Marzocchi Z2 BAM, 1680 gr -- Marzocchi Z1, 2100 gr
I haven‘t opened the Z1 and Z2 yet and just got them so I don‘t know how much oil is in there. Should have an effect on the weight. Marzocchi has listed the Z1 with 1760 gr in their ‘97 catalogue. This must be without oil which would be pretty funny. In the ‘98 catalogue they stopped listing weights altogether.
In any case, I will be servicing/rebuilding both Bombers that I got. Will be riding the Z2 and sell the Z1.
Looks like the Z2‘s color is also the better fit with the Merlin. And I do love Italian colors and the Italian mountains!!
Attachments
Bytesex
Dirt Disciple
A quick update...
The 1 1/8" steerer tube has been removed and the Z2 crown has been fitted with a 1" steerer tube and an aluminium shim. Marzocchi didn't provide 1" alloy steerer tubes (stability) so the new tube is Cr-Mo. Next up is rebuilding the Z2!
Head set and bottom bracket both were serviced and are in great condition. I had replaced the bearings in the bottom bracket at least once in the past. So they just got cleaned and greased.
The 1 1/8" steerer tube has been removed and the Z2 crown has been fitted with a 1" steerer tube and an aluminium shim. Marzocchi didn't provide 1" alloy steerer tubes (stability) so the new tube is Cr-Mo. Next up is rebuilding the Z2!
Head set and bottom bracket both were serviced and are in great condition. I had replaced the bearings in the bottom bracket at least once in the past. So they just got cleaned and greased.
Bytesex
Dirt Disciple
Finished my first Bomber rebuild (and learned a lot).
Disassembling and removing the old fork oil from the Z2. Oil seals were leaking, oil levels were criminally low.
Turned out that pilot bushings (the two cylinders with holes in them - I think holes are Z2 specific) are in great shape. I didn't ask the seller to check if there's any play in the stanchions. Replacing the bushings would be expensive. Next time I'll better check before buying an old fork!
All parts got cleaned, degreased and inspected.
The Z2 has only one hydraulic cartridge (damper) in the right leg and a pumping element in the other. Not gonna lie, the fork and it's construction is properly fascinating! 
Parts that got replaced: Oil and dust seals, all O-rings, screws, safety rings and preload knobs. And the fork oil of course.
This was lots of fun! Can't wait to try the Z2 on the Merlin!!
Disassembling and removing the old fork oil from the Z2. Oil seals were leaking, oil levels were criminally low.
Turned out that pilot bushings (the two cylinders with holes in them - I think holes are Z2 specific) are in great shape. I didn't ask the seller to check if there's any play in the stanchions. Replacing the bushings would be expensive. Next time I'll better check before buying an old fork!
All parts got cleaned, degreased and inspected.
The Z2 has only one hydraulic cartridge (damper) in the right leg and a pumping element in the other. Not gonna lie, the fork and it's construction is properly fascinating!
Parts that got replaced: Oil and dust seals, all O-rings, screws, safety rings and preload knobs. And the fork oil of course.
This was lots of fun! Can't wait to try the Z2 on the Merlin!!
Bytesex
Dirt Disciple
Well hello!
This thread is coming back to life now. After a longer search for components and a few months of hibernation this is what we're at. The Bomber fork has been fitted, a seat post been purchased and a stem has been found to replace the old 0 degree version. Sadly it has the cable guide that is useless on this bike because of the Magura breaks so I'd like to swap it. Some old new WTB rubber is on it's way as well.
This thread is coming back to life now. After a longer search for components and a few months of hibernation this is what we're at. The Bomber fork has been fitted, a seat post been purchased and a stem has been found to replace the old 0 degree version. Sadly it has the cable guide that is useless on this bike because of the Magura breaks so I'd like to swap it. Some old new WTB rubber is on it's way as well.
