1" threaded to 1 1/8" threadless fork conversion, not headset

[Indyjps]

Need to clean up the threadless steer tube aluminum chunk, left it on to seat the bearing race, as well as a little height adjustment in place of a suspension fork.

Will drill or cut slots in the threadless headtube for plug welds.

 

[Captain Awesome]

Pretty cool. Never even occurred to me to do it that way. So just adds the old crown to the stack height but in some cases I guess that could be shortened as well

 

[Indyjps]

Yep. The aluminum chunk from threadless fork can be reduced in height, really just need enough for the bearing race.

I like that it's full tube in tube with plug welds, should be plenty strong for cruising around. I wouldn't trail ride with it.

 

[Indyjps]

Changed tactics.

Sliced 1/4" or so, off the bottom of the aluminum sleeve to allow steel of 1 1/8" headtube to protrude. Full weld on base of 1 1/8" headtube to original fork, step for the race. Couple plug welds. Ready to strip and paint.

It's been fun. Time involved sure makes that Sunlite 26" straight fork look pretty good

This has really been a test run on a different project. Alum modern bike to be built into banana seat cruiser. Needs a height adjusted fork, I''ll use this method and maybe a 27" old school fork.

Would be really easy to slip a springer plate into the stack up between old fork and 1 1/8" steer tube

 

[Ulu]

I was considering doing something like this but leaving the little wings on the bottom tree to act as support for my spring bases.

However the forks I have are not aluminum but all steel. This will make things easier for me.