Ok, I get it now. I can see the end of the rubber boot in the first photo.
Could the rubber boot be sealed to the aluminum part before installation? Dpending on the rubber composition, maybe some tire bead sauce or some black rtv before the boot is slid into place. In the case of rtv, I'd give it 24 hours to cure before installation.
Another option would be trying to source nitrogen shock parts. Perhaps all that are interested could do a Google search and share details here.
BTW, I like the floss trick; I'll remember that. 8)
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Weldangrind
"I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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