I actually started on this last night but just finished up tonight. I finally removed the failing, and eventually completely failed, fork shroud/headlight mount and replaced it with some custom billet CNC machined aluminum headlight brackets. The right fork tube came undone no problem but the left tube was completely seized. I fought with it last night for a good hour before I gave up and put some Liquid Wrench on it over night. Today I bought a 1/2" drive 1/2" hex socket from the Snap On guy (I love working in a shop again
). Got home and cut off the remaining piece of the upper shroud and then used it as a heat shield as I held the torch on the joint for 5 minutes or so until it had been smoking for at least a good 2 minutes. Put the breaker on it and it finally broke loose. I also borrowed the 1/2" drive cordless impact from work which really sped up the job. I saved so much time I decided to go ahead and change the fork oil again while I had everything tore apart. Now tomorrow I can to ride to work and enjoy and the unseasonably warm weather were having right now.
And here's what I thought of the fork shrouds
Scottie