Don't take this the wrong way, JVS, but... Scotty points out that the cap is a reverse thread - you weren't tightening, were you? Sorry, but I had to ask! To battle!!!
JVS-I'm taking a lunch break, in the middle of the job right now. I've got the forks off the bike with the caps off. I thought I'd add my $0.02 while I'm here...I printed Scotty's tutorial, and have it in front of me in the garage. Everything is exactly as he's said .