Wondering if anything can be done to smooth out this surface some. Knowing the new seal will continue to leak unless replated. Even topping off fluid when needed no biggy as long as I have some dampening up front.

DT2 

A friend of mine who is into vintage MX racing has had success with pitted forks by spinning them in a lathe and sanding them with fine emery paper. He said it leaves a visible cross hatch pattern but the end result sealed well.

I spun mine in the lathe & just stropped them up with reasonably fine emery cloth. Amazing what works when times are tough. Have also tightened the seal spring by unwinding at the join & snipping it back a bit using wifes sewing side cutter things--don't tell her. Then rejoin. To rejoin i needed to reverse it a bit before joining so it sits at neutral once re-attached.
Then run fork gaiters --"boots" so ya can't see the damage lol.

Great idea guys Certainly beats trying to find a plater these days. Thanks !

You might also check into the Daiichi replacement tubes sold by DC Plastics for some models.

I have (3) sets of Daiichi tubes from DC Plastics in service and I love them. Made in Japan and very high OEM quality. Not always available from them though so I keep a set or two on hand in my shop. Just installed a set on my 78 DT400E under reztoration.  Approx. $230 a set.