Leaky oil seal again

[Human Potato]

Hi All,

The last time I posted anything here was about my fork seals.  After having them "professionally" replaced less than a year ago, one of them is leaking again so I have decided to take the plunge and fix it myself.

I am going to try the "business card" trick (but with thin plastic film) but in case that doesnt work, I will go ahead and replace the entire seal.

Removing and replacing the forks from the bike is no problem, I did it last time when I took them to the mechanic to try and save some money.  What I need to know is more to do with the dis-assembly of the forks.  

As far as I know, there are two methods.  The first is using pressure to cause the forks to come apart under the pressure of the oil.  That method really doesnt appeal to me and if that was my only option I would take them back to a (different) mechanic.  The other option is to use a tool to unbolt the fork-thingy that is hidden deep within the fork.  I have heard of people making thier own "tool" using threaded rod with some locked-nuts on the end and this is what I want to make for myself.

Has anyone made this tool?  can anyone tell me the size of the nuts and the length of the rod needed (please, no pornographic jokes).  Are there any pitfalls for the unwary as far as dis-assemlbing and re-assembling the forks is concerned?  I have the Haynes service manual, but as we are all no doubt aware these manuals tend to overlook some pretty important info.  Any help would be much appreciated...
(2001 B12S)

[chupacabra]

I had a leaky seal, I changed the seal but did nothing else, still leaked. The dealer cleaned up the tubes with emery cloth and replaced the seals. About a year later the leak was back. So I took them to a defferent shop and the  mechanic said the best way was to hit the tube with a wire wheel. He did a good job, no leaks and he cleaned them inside and out.    Its been two years and its time for me to change out the oil.

[Blade]

Check the inter tubes for pits and what not. That is what usually take out the seals.