Posted Tuesday, October 14, 2014 @ 03:40 PM
Hmm. An interesting problem Dann.
Clearly something is deteriorating since the problem is growing so I suppose it must be the softer aluminum tube rather than the steel fork end. Is that a roll pin I see connecting the two parts? And is there only one, or is there perhaps another 90° to the one visible? If it is a roll pin I'd be tempted to drive it out and have a look inside the tube to try to determine what's deteriorating before deciding how to proceed.
But as I see it you have several potential options:-
1. your steel tube and welded-in fork suggestion, but that wouldn't be my first choice.
2. if the aluminum tube shows internal wear then replacement with new, suitably sized tube.
3. if the aluminum tube is in good condition then swaging the end to a smaller diameter tight fit might be possible.
4. again assuming the tube is in good condition, might it be possible to reduce the internal diameter by the use of aluminum brazing then reaming to size. The snag with that idea is that generally the brazing is harder than the aluminum.
5. as 4. above but instead using a resin filler to close the internal diameter to a snug fit.
With all but the welded steel solution I would expect there to be some sort of mechanical connection, like the roll pin(s) already mentioned.
I should add a disclaimer that I have never done any of these things and I make these suggestions merely as food for thought. My first action, though, would be to have a look inside the tube.