Methods and apparatus for structural reinforcement of vehicle suspension members

A method of creating a vehicle suspension fork comprising:

• conditioning a first portion of said vehicle suspension fork to a non-ambient temperature;
• precisely positioning and engaging said first portion with at least one second portion of said vehicle suspension fork while said non-ambient temperature remains substantially as conditioned, wherein after said precisely positioning and engaging said first portion relative with said at least one second portion said vehicle suspension fork comprises:
• a crown having a first fork tube opening and a second fork tube opening;
• a first fork tube engaged in said first fork tube opening;
• and
• a second fork tube engaged in said second fork tube opening;
• holding and moving said at least one second portion with respect to said first portion via one or more retainers as a part of said precisely positioning and engaging;
• and
• returning assembled portions to a substantially ambient temperature, wherein said returning assembled portions to said substantially ambient temperature creates a compressive hoop stress in said first fork tube and a tensile hoop stress in said first fork tube opening but creates no substantial axial stress in either of said first fork tube or said first fork tube opening, and creates a compressive hoop stress in said second fork tube and a tensile hoop stress in said second fork tube opening but creates no substantial axial stress in either of said second fork tube or said second fork tube opening.