well, I thought I got a good deal on a pair of forks off ebay only £25.00 and they looked usable, thought I would rebuild these with new bushes and then swap them over to save too much down time.
Went out in the shed last night to strip them down and found the fork spacers are made out of 2 cut bits of plastic tube (I don't think there supposed to be plastic). The forks had been filled with ep90 (gear oil) and the sliders are gouged (out of site under the seal).
So in all a bit of a waste, but at least I have some fork spares now (lol).
It looks like I will have to take the bike off the road for a couple of days for the fork rebuild and calliper rebuild (doh!)

 

Any pictures?

 

Wheelnut, fork spacers are usually metal from the factory, but I've re-valved and re-sprung a few 900RR forks with Race Tech goodies, and they recommend to use schedule 40 PVC to cut new spacers for proper preload. Usually the spacer will be longer than OEM to achieve this. As long as it's schedule 40, and the spacer sits on the fork spring washer and fits under the fork cap, they're plenty strong.

Here's an online article about something similar I did:
Race Tech Gold Valve Cartridge Emulators Review | Rider Magazine

 

I've seen heavy wall PVC used for after market rebuilds.
It was a long time ago so I don't know for sure but I think I remember the Progressive spring kit I installed came with PVC spacers but I used the old metal ones.

 

Pipe or tube is incredibly strong when compressed longitudinally.

If you don't believe it, cut a short length of plastic drinking straw (about an inch), with scissors and then hold it between your thumb and forefinger. Then try and squash it.

 

your right they are strong enough for the job, when I rebuild the forks on the bike, I will measure both sets of springs and use the better set, I work in the aluminium industry so I can make some spacers up as needed, I would love to put new springs ect in, but its the usuall (money) that holds it up