Bare Bones Bicycle Fork Jig

Step 3 Making the dummy axle

First, drill down along the pivot axis with a 9mm drill bit to make room for the front axle.

Then in the center, drill a 3/16 or 5mm hole down to the axle hole and tap it M6 for the set screw

Finally, you will need to make the old counterbores deeper so that the mounting screws will sit below the axle. Use a drill or end mill slightly larger than your bolt heads. A 9/16" ought to do it. You don't have to be precise about the depth, just make it deep enough to clear the bolt heads.

Next, tap the ends of the short piece of extrusion to M8 threading. You might want to run a 17/64 drill bit down the hole first to make it easier to tap, though it's not needed.

Bolt the dummy axis mount to the end of the extrusion, squareing it up to the sides.

Finally, slide in your 9mm axle, add your locknuts (I only used one set but 2 would be smarter) set to 101 mm spacing, and center it, locking it in place with the set screw.