2001 kx250 front won't bottom

First up,hello all. I am new here :) . I just bought a used 2001 kx 250. I'm a big guy at 280. I rode the bikewith the stock springs and could not get the forks to bottom out. I knew something was wrong. I ordered set of stiff springs for the front and rode it with the oil level down to 110mm (70mm is stock). The forks still will not bottom.Ive got a zip tie on the left leg to help me montor the travel. It seems a though they are getting to about where I have 3" of travel left and just not moving any further. I did change the oil when I swapped the spings in. It looks like I'm going to have to tear them down. What should I be on the lookout for? Are there any special quirks when assembling the forks? I've been changing my own oil, springs and seals for years now but never got into valving. I do know the basics . I also know that there is something wrong with these forks. What could be causing the binding? I pulled the handlebars off and was able to compress the forks completely when I unscrewed the caps =not the axle binding. Help :bang:

I'm getting 9 and a half inches worth of travel. There is about another 2 inches to be picked up somewhere. I'm wondering if one of the bladders could be punctured and consuming oil / givig me a false oil level reading or something. I've searched this forum and did'nt find anything simular to what I'm experiancing. Anyone have any more ideas?