Hi All,
At this stage I would imagine that most BSA's running have had the fork stanchions replaced at some time

If there is oil in the forks, the fork bushes should not clash on extension, because there is oil trapped between the upper and lower bushes as the forks extend
Early forks did not have the two oil holes in the stanchions
I found some "new" bushes recently that the top edges were chamfered
These would not work as the circlip would not hold them solidly in place, I machined off the chamfer and added thicker shims. Thin shims are waste of time anyway*ex*
I know that people have had different experiences with the Dow type dampers!
Julian,
There's a ball valve in the damper that allows oil to flow through on compression, the ball closes on extension
forcing the oil down around the outside of the valve body giving rebound damping
in the "normal" forks the damping is achieved by the oil being forced in an out through the holes in the stanchion
to the ever changing space between the bushes
I added extra oil so the damper valve is submerged on extension
Thinking out loud

Was the TD damper rod length calculated to work with the longer TD fork bushes that make the overall fork length
2in. shorter

The TD top yoke restores the ride height
A design flaw on BSA forks is that water can easily get trapped in the seal holders and sucked into the forks

Regular oil changes are a must

John