TomR Posted January 9, 2007 Report Share Posted January 9, 2007 How to:Remove & Fit a headset (frame and forks).What you’ll need:5mm allen key (and a 6mm if you run a headlock gadget)Large punchHammerNylon/rubber malletA couple of bits of woodNice thick greasePreferably someone to helpMethod - Forks:Remove your bars and stem, and with the mallet give your steerer tube sharp but not too hard taps in various directions, this should make removing the wedge stopper thingymabob in your headset a lot easier, as opposed to just trying to pull on it or get it out with a screwdriver.Remove your forks and whatever bearings/seals are in the headset, remember which order they go in and which way the bearings face!If you’re changing the forks or installing a complete new headset, read this part. If not just skip it.Remove your front brake and wheel. Clean the forks up and flip them upside down so the legs are pointing up. With the hammer and punch give some sharp taps round the edge of the bearing race (Ie left, right, front then back) to ensure it comes off straight.Get the new forks and existing bearing race (or vice versa) and clean it all up. Put the forks over a piece of wood on the vice or other solid object like below (get someone to hold them if possible). Put a smear of grease round the inside of the bearing race and place over the steerer tube. You can use a punch or a large flat bladed screwdriver for this bit, but I find it easier with a bit of metal tube. As with removal, give sharp taps round the bearing race to re-fit, when it’s done hold it up to the light to check its seated correctly. Method – Frame:With someone else holding the frame steady, place the frame over the piece of wood on the vice/solid object. Put the punch down the head tube, and give some hefty taps round the inside of the lip like before until the cup drops free. Flip the frame over and repeat.Health warning! If you can, use a nice heavy hammer and a bloody long punch, the punch I used was a bit short and slipped, resulting in me crushing my thumb between the headset cup and a 2lb ball-pane hammer – not nice!Take the lower cup and the frame you’re putting it into and smear a bit of grease round the edge. With your glamorous assistant holding the frame up (if you’re sad like me) line up the text/logo on the headset as you want it.Get the hammer/wood or a decent nylon/rubber mallet and smack like mad until it’s seated correctly in the frame. Repeat for the upper and hey presto, you’re done.When it comes to fitting bearings I think I’m pretty oldskool in the fact that I cocoon everything in sight with huge amounts of the thickest grease I can find. Get a big blob and smear it round the upper and lower cups, put the bearings back in the correct way round then smear even more grease over the top. Cake the bearing race on the forks with just as much and refit your forks. Slide whatever seals, races and covers you have back over and re-fit your stem and top-cap, then go forth and ride the thing.If anyone spots any errors or has a better suggestion on how to do something, PM me and i'll edit. Quote Link to comment Share on other sites More sharing options...
fyfey Posted January 27, 2007 Report Share Posted January 27, 2007 Cheers for that! I've been wanting to know how to do it for a while (as I'm hopefully soon building a bike)So you don't need a headset press tool?? Just a mallet and some wood? Quote Link to comment Share on other sites More sharing options...
Dan6061 Posted January 27, 2007 Report Share Posted January 27, 2007 Headset press tools fit headsets. Nice method, and really healpful topic. -Usually what I do.If you want to do it properly, and not risk flaring the headtube by having the cups come out at dodgy angles, then buy one of these:Basically, you insert that into the headset so it expands out inside the headtube, then bash the top with a mallet. Saves having to bash, move screwdriver/whatever round, bash, move..etc. Quote Link to comment Share on other sites More sharing options...
fyfey Posted January 27, 2007 Report Share Posted January 27, 2007 (edited) Headset press tools fit headsetsYeah I know that! But he's saying just smack the cups on to the frame...Get the hammer/wood or a decent nylon/rubber mallet and smack like mad until it’s seated correctly in the frame. Repeat for the upper and hey presto, you’re done.So I guess a Press Isn't needed? Seems a bit dodgy just smacking it on, could mess up the cups surely?Also on new forks won't you need to install a Star Fangled Nut?Looks easy enough with the Park Tool Threadless Nut Setter (TNS-1) - £15 on ChainReaction. A very nice guide on using this tool as well on the Park Tool website. Edited January 27, 2007 by fyfey Quote Link to comment Share on other sites More sharing options...
TomR Posted February 1, 2007 Author Report Share Posted February 1, 2007 Aslong as you steady the bike (preferably with someone else) and make sure you constantly check the cup alignment with the frame then it's ok. I've not had a problem in the however many years i've done it this way. These threads are kinda aimed at people without the special tools, as generally if you happen to own specialist tools then you'd know how to use them.I've got to cut a pair of forks down soon (i'm doing a how-to on that aswell) so i'll add the star fangled nut info in here with some pics when i update. Quote Link to comment Share on other sites More sharing options...
fyfey Posted February 18, 2007 Report Share Posted February 18, 2007 (edited) Now trying to fit my headet, having some trouble getting the cups in straight. I've got an Echo headset with the sealed bearings so it's annoying tapping it in without hitting down on the bearings.Anyone had some experience fitting these headsets? It keeps going off a bit and whatever we do to hit the other side in it wont budge. So tap it out and try again!EDIT: Finally done it! Our main problem was keeping it all solid when we hit it with the mallet. Once there was no "bounce" when hitting it in, it went in a lot easier Also use a nice hard wood, chipboard worked crap! Just thought I'd share this as to help others who maybe doing it.Cheers,Fyfey Edited February 18, 2007 by fyfey Quote Link to comment Share on other sites More sharing options...
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