Ascot FT500 Fork seal rebuild with problems

[the great gazoo]

I finally got the Ascot inside & broke down the front end, the seals were leaking pretty bad.
As I got further into it, I realized no 'ordinary' set of snap ring pliers would work, I broke one snap ring & the other was crusty, so I'm ordering those. First thing I found was the drain plug on the right one was broken off & there was no oil in the right fork at all(it kinda made a 'springy, sqweeky sound when it was on the bike), see the pic. I'm wondering if there's enough meat left to try & tap new threads? I was also thinking about JB welding it, only because I was telling the story to a buddy of mine, & he happened to have a couple tubes in his pocket& gave 'em to me. Bur it's prob'ly not a good idea, seeing how the tube is under pressure. So tap it, or bit the big one & get a set off FleaBay & hope they're not too destroyed on the inside.
OK, here's my question, the emulsion tube at the bottom has the 'return' spring, & a cup that goes on the end of the tube, see the pic. The spring slides all the way up & down on the tube, so how is this doing ANY return springing? Do I have it on there wrong?

[Vealmonkey]

The spring cushions the blow on the fork tube if the forks ever fully extend. The big springs are for the compression of the fork, and the fork oil weight and the emulsion tube controls how fast the fork returns back to normal length.

[El Camexican]

I'd get that bust up hole TIG welded solid and then drill and tap it.

[the great gazoo]

Hey now, that's a great idea. thanks, ElCamexican!
Pat, I'll be over Saturday with the forks & I'm gonna have to kidnap you for a ride down to Bowie to get that SX, if the guy hasn't sold it yet.

[Vealmonkey]

What have you done about the busted up fork drain hole? I was thinking, simply tig welding, drilling and tapping won't fix it. Your drain hole is recessed. You can drill and tap, but it needs to have a flat surface for the sealing washer to be able to seal and that flat surface is supposed to be recessed down inside, and a tap won't make that flat surface. You may be able to fudge it by grinding down the busted part till you reach the flat surface, tig and drill and tap, but then your drain screw will be exposed. You need to decide what you want to do. Also I need a size and pitch to see if I can get a tap that will fit and what is the right drill bit to use. And I may have to back out for Saturday as well. Long story.

[El Camexican]

What have you done about the busted up fork drain hole? I was thinking, simply tig welding, drilling and tapping won't fix it. Your drain hole is recessed. You can drill and tap, but it needs to have a flat surface for the sealing washer to be able to seal and that flat surface is supposed to be recessed down inside, and a tap won't make that flat surface. You may be able to fudge it by grinding down the busted part till you reach the flat surface, tig and drill and tap, but then your drain screw will be exposed.

I figured he could just fill it with weld, grind it flat, drill & tap and use a button head bolt with a copper washer. If he wants it recessed he'll need to take it to a machine shop. Ya'll have fun.:beer

[the great gazoo]

Aw crap, well I guess you 'owe' me Pat, for me forgetting the past Sunday. LOL. But seriously, I'm thinking about unloading this bike & getting another dual purpose, soooooo....Am I such a bad guy if I just tig weld the hole solid? I mean crap, the couple times I've done fork seals I drained them from the bottom anyway, & this is a street bike, giggity.