Thanks for the links! I'm relatively new here and missed the thread entirely, good read, CAD file pretty awesome too.

One question to the experts: The HRC plates, anyone tried them? I can easily have them remade and willing to try them once I figure out what I'm doing with a shock, are they designed for a 17" wheel or ...?

I can rebuild the shock (with little assistance) and it would be the easy option, but the Hornet shock I have is on loan as the owner wants back at some point as he intends to keep the Ohlins if he ever sells the bike, so I don't really want to re-valve it and than have to do it again. I would look for another one but those bikes are rare in US.