A method of assembling a suspension fork assembly comprising components comprising a fork is disclosed. The fork comprises a steer tube and spring assembly tube with cap insert and insert assembly and damper assembly tube with cap insert and insert assembly and leg fit within the spring assembly tube and leg fit within the damper assembly tube. The method may comprise the steps preparing each insert assembly for bonding with an adhesive bond and applying adhesive to each insert assembly to provide the adhesive bond and installing each insert assembly for the fork and aligning at least two of the components comprising the fork in a fixture and curing the adhesive bond for each insert assembly. The fork comprises a composite material such as carbon-fiber material with components attached by an adhesive bond. The fork may comprise an aerodynamic profile. A tool for installing/removing a piston assembly is also disclosed.