Lockout knob for Zoom suspension fork

Motivation

• lost the original knob before taking measurements
• designed for Zoom 188DS AMS, may work with others

Design

• stumbled upon this repair video: Suntour Fork Lockout Repair
• turns out there's a tiered & splined plastic piece that features a press fit 4 mm hex rod

• hex rod actuates the lockout
• it feels like the hex rod is grabbed by some internal mechanism lightly to retain it axially
  • as of rev 4, there is no designed feature to further retain the knob axially – use at your own risk
• as of 2023-09-11, still under development
  • design recycles the hex rod which is about 30 mm long
  • I used an arbor press to liberate it from the OEM plastic part & to install it into my PLA part

Rev 4

• added 2023-09-16
• seems to work well
• rode 100 miles or so without it falling out, hitting some rougher bumps

Prior art

• similar part on Thingiverse
• Suntour lock lever overview with views of different actuation possibilities