Chris,
Thanks, I am very happy with the reliability of the telescoping pants setup. Fairly quick to do too. Most of the time that I spent on them was in the planning. If I were to do it again, I would make the sheathing out of fiberglass instead of aluminum because the aluminum rubs against the fiberglass lower pant and leaves a dark residue. The residue wipes off easily enough with Windex though. I think fiberglass would have been easier to do also since I could have just waxed the pant in the area that I covered with aluminum, applied fiberglass and epoxy, wrapped it all tightly with wax paper or plastic wrap for a smooth finish, remove the cured fiberglass sheath and then cut out the 1" wide section from the pant. It would have made a perfectly fitted sheath for the pant that doesn't leave a dark residue. Oh well, something to remember for future projects.

I got the stock wheels to fit in the Robart fork by taking a disk sander on my electric drill to them. I used 80 or 100 grit I think. I'm having a hard time remembering how I got the axles to fit. Could you post some closeup pictures of the problem you're having. I'm having vague memories of just replacing the brass inserts with larger brass tubing that fit over the Robart axles. If I remember correctly, this required drilling out the plastic hubs of the wheels to get the larger tubing to fit.