Originally Posted by
JohnDThompson
I hand file the keyway into the forks I build. It doesn't have to extend all the way to the end of the threads; but just far enough to hold the toothed washer.
I cut my own keyways also, I line up center and put two pieces of painters tape the length of the slot I want to cut and use a 4 1/2" hand held grinder with a 5" cut off wheel to cut my slot then chase with the right fork tube tap. This has helped keeping things tight using a keyed washer.
Glenn