I just had this same problem. Discovered that the fork crown race comes in more than one size. You can either find a headset to match the fork crown, or do what I did and have the fork crown cut to match the headset.
Here's a link to the Park tools site with instructions: http://www.parktool.com/repair_help/howfix_forkmill.shtml
Fred ********************************** Fred Yavorsky Jenkintown, PA email@example.com http://twistcomm.com/FredBikes.html
> From: Michael Davies <firstname.lastname@example.org>
> Date: Mon, 11 Oct 2004 11:26:03 -0700 (PDT)
> To: email@example.com
> Subject: [CR]Headset size question
> Is there something fundamentally different in size
> between a 1" headset on older English bikes and the 1"
> headsets currently available? I recently retrieved
> several of my old bike frames (from childhood) from my
> parents basement as I wanted to ride fixed gear and
> this seemed the most economical way to go about it.
> Among these frames are a Viking (1950's vintage, I
> think) and a Claud Butler (early 1940's I think).
> Unfortunately, both these frames were missing their
> headsets, and when I attempted to use a 1" headset I
> had on hand (from a totalled 1989 Trek 1500) I
> discovered the bottom race would not fit the fork on
> either bike...the diameter of the raised section at
> the bottom of the fork is slightly bigger than the
> internal diameter of the race, meaning the race would
> have to stretch quite a bit to get it on there. I've
> solved the problem temporarily by installing the Trek
> fork and headset in the Viking....I now have a rather
> Frankensteinish looking bike with a hideous looking
> frame and creaking 60 year old 27" rear wheel with BH
> airlite flip-flop hub, attached to a spiffy looking
> front fork and 700c front wheel. It rides nicely
> Am I overlooking something in getting the current
> headset to fit the old forks and if not, does anyone
> have the correct headset for sale? I'd really like to
> get the Claud Butler back on the road as it has great
> sentimental value to me.
> Thanks Mike Davies
> St Louis