I fixed the one with the rebound clicker issue. The lock nut was on backwards and didn't thread down onto the damping rod far enough.
The nut is counter bored which I didn't notice at assembly time. That lets it thread down the rod farther, which let's the top cap thread on farther which puts the rebound adjuster in the correct range.
The other fork, that won't come apart, is well and truly knacked.
I'm heading to the shop now to machine special aluminum vise jaws to grip the stanchion tube so I can remove the lower section and feed the stanchion back up through, and out the top of, the fork tube.