This isn't specifically about a V-Strom fork cap, though I'm sure the caps on a Strom can suffer from the same issue. I know a lot of guys on here have a lot of machining experience, so I'm seeking some advice.
Like a lot of ham fisted mechanics, I bunged up one of the sides on the fork cap nut when I was removing it from my Super Tenere while changing the fork oil. It's not bad, and I'm pretty sure I'll be able to remove it again, but it got me to thinking about a better way to get the cap off than using the soft aluminum nut.
I was considering two possibilities:
1) Drill two shallow holes in the fork cap on either side of the nut, and use a pin wrench to remove the fork cap in the future.
2) Machine an aluminum donut the same diameter as the existing for cap. Drill a series of holes around the circumference of this donut (I'm thinking maybe six holes, like a #6 size). Then tap corresponding flat bottom threaded holes into the top of the fork cap, and screwing this donut to the top of the cap. Since the threaded holes would have to be pretty shallow, I figured that six of them would provide a pretty secure attachment. Then, drill holes into the donut that would correspond to the pins on a pin wrench. The donut would be 3/16" thick, which should provide plenty of depth for the pins on the wrench.
The biggest downside I can see is that I don't know how deep I could safely drill holes in the fork cap.
For those of you who have machining experience with aluminum, would this work? I've attached a photo of a Super Tenere fork cap. These things are $300-400 new, so if there was a way to salvage the old one, it would be worth a shot.