My reasons for the swap have nothing to do with anodizing issues. I'm looking for better ride, more travel and I love working on projects like this...I enjoy the problem solving and the challenge involved. The gain from these SSS units will be HUGE for me and the riding I do. I do agree that for someone riding the occasional back road, it's overkill and not worth the cost or effort involved. By limiting uptravel with oil level, you'll be detracting from the awesome ride twin chamber forks provide. One of the benefits is that you can run a much lower oil level in the tubes because the cartridge is sealed and has it's own oil so cavitation isn't an issue. People add sub tanks to their forks specifically to avoid the effect of the rising rate air spring due to a small air gap. I'd be looking at options to space the bottom stop so it does it's thing sooner (if possible) but that's just me. Maybe one of the suspension gurus will weigh in. My forks are currently springless and I've fully compressed them, no issues with the fender/bracket clearance. I remember you posted a pic of your high fender set-up. IIRC, the brake line runs under triple and your bracket is spacer down, correct? My bracket is 6mm thick and right against the bottom of the triple...that's likely the difference. I need to notch my SW Motech skid plate though as the tire contacts it but that's happening with the stock forks too. Yes, if I don't remove the plastic rings on the sliders, the rivets on the rotors will and in a spectacular fashion! 1/4" clearance at full stuff; just enough room for the fender to bolt up. My spring rate would be high for a normal size person but I'm 290lbs (over 130kg) in gear. I ride similar terrain to you (based on your pics and videos). Lots of loose rock, embedded rock, square edges, ruts, logs, water bars, washouts etc. My tuner told me 0.75kg/mm would be the lightest spring he'd accept. I went on the RaceTech spring rate calculator and picked a KTM 990 as it's very close in size and weight (no Africa Twin listed last I checked). I plugged my riding style, weight etc in and it spit out 0.756kg/mm. My current 0.69kg/mm springs are too light. I've run a single rotor and caliper with a master set up for dual, I didn't like the stiff lever. I'll give it a try but fully expect I'll be looking for a smaller MC sooner than later. The shim material is galvanized so it shouldn't be an issue. I'll give it a shot of paint at the peened edges as some of the coating will have flaked off there. I didn't make a new axle, just lengthened the stock one. I beveled the edges of a 17mm impact socket and the axle at the 25mm end. Lined up the flats on the internal hex using a 17mm nut and welded the socket on the end. Stuck it in the bandsaw and cut it a hair over 250mm overall. Then we threw it in the lathe and machined the weld and socket down to 25mm to match the axle diameter and squared up the face... looks stock. Lengthened by 8mm (0.5mm protruding from the right lug).