I know this all a bit old school and retro for most people on here ie: 26", flimsey, undersized tubes etc, but as I started it ages ago I thought I would try and finish it at least. Onced finished I would love to do similar to a more modern fork, I suppose what Shift-Up is doing is the nearest.
Anyway as I had a few old Sid WC's sitting in the garage, I had already back in '06 done a single leg conversion using parts from several forks. So now I am reusing and moding some of the old carbon internals that mmm-bikes produced ages ago.
The carbon steerers are to be sanded matt to match the existing bare/matt carbon of the rest of the bike. I had a load of old Sid lowers that I have stripped, sanded and removed the old cantistuds. I will replace the old bushings and seals as needed but have not removed excessive amounts from the bridge and dropouts so are they should still be as robust and usable as originally. I have reprayed a couple matt black with gloss decals to match the frame.
As to the internals, I will replace the alu/plastic screw in cap with a carbon one, nylon bolts/nuts and the SID damper unit has been stripped and the has carbon tubes instead of the alu originals.
Previous complete forks, canti removed and resprayed by paint shop! (obviously they didn't bother to strip and only painted over the old silver paint! My stripped lowers, notice that some lowers were lighter than others, I had to weigh all of my 15 sets to find the lightest and stripped those. Then a minimal matt black coating and decals and ended up saving nearly 90g over the previously modified and sprayed lowers.
As to the internals, this is a joint project with another member who has loads of the original mmm parts and we trying to make up as many fork kits as possible. Hope to have a ultra lite dual damper set and also one with the modified lockout as well. Should be between the mid 950gs to maybe 1100g for both versions.
here's the alu damper unit and the pieces that need the carbon tubes to make up the single legged dual air/oil unit, the carbon caps and a moded dual air damper for the lockout side.