"and all was going well until the rebuild." < Lol, we've all been there.
Without the spring in place and with the inner tube (upper tube) fully compressed the inside of the outer tube and the outside of the inner tube can make contact, then stick when the bottom bolt is tightened.
(After I read that a few times I could actually understand what I wrote).
Anyway... Two ways you can go.
1) Temporary install the top cap bolt then hold the inner tube in a padded vice (clamping at the top, top cap area) and give the outer tube a good solid pull. It will probably come free.
-OR-
2) Remove the bottom bolt then reinstall it making sure to keep the inner tube in the 'up' position.
Without the spring in place and with the inner tube (upper tube) fully compressed the inside of the outer tube and the outside of the inner tube can make contact, then stick when the bottom bolt is tightened.
(After I read that a few times I could actually understand what I wrote).
Anyway... Two ways you can go.
1) Temporary install the top cap bolt then hold the inner tube in a padded vice (clamping at the top, top cap area) and give the outer tube a good solid pull. It will probably come free.
-OR-
2) Remove the bottom bolt then reinstall it making sure to keep the inner tube in the 'up' position.
