Marzocchi Star Fork restore

[InFaasion]

Got this fork some months ago with a frame I found. Frame is cracked on several places and fork is seized. According to previous owner it was fixed not to have any suspension anymore, but when I checked I found it was just full of water! Draining the fork made it move again, so the hunt for information and parts started. Came across Dr.Marzocchi’s website where a lot of info and spares are found, including 2 brand new lowers! Knowing someone welded a disc mount on the right lower this was a welcome find. Ordered inclusive all O-rings, bushings and small parts I was ready to go…but time wasn’t.
Now it is so starting to disassemble the fork and just hope not to many parts I didn’t find are corroded or worse. Took me a lot of time to remove the two air chambers alone and don’t expect an easy job.
Opening this thread to show progress and when finished this fork will be mounted in my just acquired S’bike with full Campagnolo group and Modolo cockpit. It will be all Italian in the end. I will post and update when new steps are made. Enjoy!

 

[Dr-Zocchi]

Happy to follow your rebuild! Drop me a note, if you need anything else

 

[InFaasion]

Made some progress today. Took apart the lowers and found another splash of water in both legs! Was able to disassemble all internals without to much hassle and only one part of the bottom out spring was slightly rusted, but cleaned up nice.
Installed new air valves plus new dust caps and replaced all bushings and O-rings. Cleaned both inner legs and one was just clean on the inside, but the other leg has some corrosion inside. Was able to get out most of it and what is left will not effect the working condition of the fork.
Simple but strong inners and clearly a glimpse to the motorbike forks from that era Marzocchi made.

 

[InFaasion]

Short update: cable hanger and arch are separated. Was not my intention to do but apart from the hanger being twisted and bend, one of the welds was cracked. Decided to keep the arch without I filed away the remaining material and gave the arch a base layer. Tomorrow it will be gloss black, together with the crown. Pics will follow.
Not a lot of progress but hey, who is in a hurry

 

[InFaasion]

It’s done (a small cosmetic detail left) but fork is back in working condition and looks stunning!
Pressed in new bushings and seals, hardest part was the teflon bushing folded around the inner leg and then pushed into both lowers. Added new oil and put the whole under pressure. Some hisses here and there that stopped after a minute or so. Tomorrow pressure check and try to get the decal on left leg off and reattaching on the right side. That’s the only flaw left since both lowers are right side legs. Hope it will come off intact but already really happy with result.