So, first things first, rode Huber today for an hour, and pretended the park wasn't a disaster (well, really, it's not, but I try not to consider that 99% of the dirt that's churned/rutted in the turns is horse crap) in order to get the creative juices flowing. Then I grabbed my thinking cap, a handful of 3/8-24 nylon screws, and my drill:
Then, determined not to spend a bunch of money on a tap that I would only use once (okay, twice), I grabbed a suitable 10-24 screw and had at it with a fiber-reinforced cutoff wheel to make 3 channels, then the belt sander to give the nose a nice taper. I zipped a bit off the diameter of the screw while I was at it. The flathead slot was fiddly, but more than sufficient to tap nylon.
Next step, screw the nylon screw into the One-up tool, and use a flush-cut saw (for dowelling!) to cut flush with the end. This was fiddly, but gave good results.
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The first one (not pictured) was better centered. Drilled freehand instead of using a press.
Finally, I grabbed a pair of curved, smooth jaw pliers to turn a tube from Dynaplug into the hole. Remember, I took a bit off the OD of the screw "tap" so it would be a tight fit.
All the little dealies fit nicely into the small tube that comes with the tool. The new ribbed o-ring fits into Rockshox stuff, too--it's not dead silent like the fork bung, but it's quiet enough (and that plug is ugly AF). I'm going to take a page from Grandpa and his Camillus electrician's knife, and sharpen the flathead screwdriver bit on the side to make a knife that can cut the plug flush.
I also took the opportunity while it was off to clean the threadlock that One-up put on the chain tool pressure screw. Don't have any idea WTF they were thinking, other than maybe securing future customers for replacements when it immediately stripped trying to break a chain?