Rockshox Manual Front Suspension Lockout Switch

This is a replacement lockout switch for a front suspension Rockshox fork.

My fork is a coil fork, so I don't know if it works with their air forks.

It was attached with a sheet metal/wood coarse thread screw. An octagonal inset in the bottom mates to the fork, & is used to actuate the lockout itself.

My fork is a Rockshox Recon Silver, 100 mm travel, G2 geometry. I can't speak to compatibility on other forks. The crown geometry may not be the same, so the switch may not fit.

How I Designed This

Took dimensions off my own switch.

I guessed the countersink angle to be 90 degrees.

I optimized the switch to clear obstructions on the fork first & to get a good fit with the octagonal piece. I then increased the wall thickness until it would run into the crown of the fork, to bolster strength.

Updates

25 Jun 17: Octagon feature is too big. Want nominal 9.5 mm circumscribed circle for a looser fit, 9.4 mm for an ideal (tight fit). You'll have to press the switch on if you choose 9.4 mm. CAD will be 9.4 mm