How would you get THIS off?

A new fork for only $100? Thats what I would do.

Lathe and end mill. Or send both forks to us and we'll take it off, plus service them.

Don't quite understand the JB weld comparison, the ice is to keep the seized aluminum cap cold while the tube is heated.

Heat the outsize tube and ice cube the inside nut. Repeat with wd 40 or some other penetrating oil between repeated applications.the metals expanding.and contracting will sometimes break the chemical bond that happens between dissimilar metals Have some patients as this kind of situation can get you too pumped for the task at hand.

No fancy stuff I have removed 100+ caps that look just like that ( and put most of them back on because customers can be cheap lol) slide it up a few inches in the trip trees and use a pipe wrench no heat or freezing no fancy stuff only grab the cap not the the tube it will come off we wouldn't lie to ya lol

Sorry Ruffus I misunderstood what you said. I thought you were intending on using the ice to grab the damaged end as a custom formed socket. Good idea but I thought the JB weld would be stronger. Cam.

I definately would try a monkey wrench first, however, my concern would be the aluminium galling inside the internal thread. It would be a PITA to remove torn up bits of ally stuck in the thread. If it felt like it was tearing the ally thread, I'd stop and cut: hack saw, dremel, grinder etc.

Or first place would be...

Did you fix this already!? update?

UPDATE UPDATE UPDATE !!

I got the little F*$%# off. THANKS FOR ALL THE INPUT GUYS! What a great forum this is. As I am new to this, I'm sure I'll have more questions and run into more problems....but as I get better at working on the bike....I hope to help other greenhorns.

This is what I did to get it off:

1. Loosened top tripple tree bolts.

2. Used hack saw/dremel to cut around existing bolt head all the way down to the steel stanchion tube. This exposed more surface area for a socket to grab.

3.) purchased a nice set of air tools and used an impact driver with 6 point socket. NO HEAT WAS USED.

4.) purchased new cap.

THANKS AGAIN GUYS!!!

Time and money, works. Good job. Definately more refined way.

Here is the bolt after the modification and removal! THANKS EVERYONE!