How much play in a spring suspension fork is normal or safe? I have (had) a basic Suntour spring fork on my hybrid and when I took it into the bike shop a couple months ago I was told the fork was excessively worn and needed to be replaced. Long story short I went cheap and put a solid fork on it which it turns out massively changed the geometry to the point were I'm putting pedals into the dirt on bench cut trails, even without roots.

I still have the old fork and it's something near 2 inches taller than the new rigid fork. I believed the shop at the time when they said it was worn but now I'm wondering. Holding the upper and lower portions of the fork I can feel it shift slightly when I try to bend it but it doesn't move visibly that I can tell. 

Is it still reasonably safe as-is, should I get new bushings from Suntour for it and see if that helps, or should I accept it as dead and spend the money on a new suspension fork that is the right height?
It doesn't sound like it's dead yet.

Play means that the bushings are worn out.

If you continue to ride it just how it is, you will end up damaging the stanchions. However, it is not dangerous to your personal safety to do so.

Replacing the bushings seems like the best option. I doubt the stanchions have any damage if it's only a tiny bit of play like what you're describing.

It is also worth noting that the responsiveness of the fork (how well it "floats") would likely be much improved if you gave it new lube and bushings.