I am restoring my childhood bike which i got back from the paint-shop yesterday. Like an excited kid, i started bolting bits on last night but I have a bit of a problem. Originally the bike had an old ACS style rotor / spinner but being as they were rubbish and I quite want my bike to be rideable, not just a museum piece, I have opted to fit an old mk1 oddyssey gyro which is still in period (just) but far superior.
Anyway, I fitted the tioga beartrap headset as usual, dropped on the toothed locking washer followed by the upper gyro tabs but when I went to put on the final locking nut of the headset, it was very clear that there wasn't enough thread on the top of the forks to fit it. If I leave out the toothed washer, it fits fine.
My question is, has anyone else had this problem? What is the best way around it? I am thinking
1. Run with the beartrap and leave out the washer - but i am worried that it will come loose all the time.
2. Switch to a standard headset - but i am worried that it will come loose all the time!
3. Can anyone recommend a headset that does not come loose but which is less bulky?
4. Has anyone ever ground down the toothed locking washer and / or the gyro tabs (both are pretty thick) to make more room and if so was it successful? Did it make the headset weak / the brakes spongy?
5. Has anyone got anyother suggestions like tapping tabs into the stem - although I don't really want to molest my beautiful GT stem?!
Many questions I know, and it is a long shot that anyone else has even had such a problem with such a combination of parts (hutch trickstar / tioga beartrap / mk1 gyro) but any suggestions would be welcome. Many thanks.
Jason