Bicycle Mechanics - 1" headset doesn't fit 1" fork or steerer tube

Did an inch used to be smaller? I have an original Cambrige, Massachusetts-built Merlin Mountain frame (circa 90's) with the 1" head tube. I can't seem to get ANY headset race to fit in the steerer tube. The races are just 32/nd of an inch too big. I have tried both a new threadless Ritchey, and an old Campy (threaded) headset as well as some other brand, all are one inch and all are a 32nd of an inch too big.
I have built up at least 10 bikes-- old new, both threaded headsets and thread less: Campy, Stronglight, Ritchey, Aheadset, Shimano, Mt bikes and road bikes,but this is just plain weird to me.... Any help would be appreciated. Also the fork race does not fit, by about the same 32nd of an inch.. too small to fit the fork, but that doesn't worry me as much as getting something to fit in the steerer tube. By the way I would like to set this up threadless but will go with anything that fits.
thanks.

Did an inch used to be smaller? I have an original Cambrige, Massachusetts-built Merlin Mountain frame (circa 90's) with the 1" head tube. I can't seem to get ANY headset race to fit in the steerer tube. The races are just 32/nd of an inch too big. I have tried both a new threadless Ritchey, and an old Campy (threaded) headset as well as some other brand, all are one inch and all are a 32nd of an inch too big.
I have built up at least 10 bikes-- old new, both threaded headsets and thread less: Campy, Stronglight, Ritchey, Aheadset, Shimano, Mt bikes and road bikes,but this is just plain weird to me.... Any help would be appreciated. Also the fork race does not fit, by about the same 32nd of an inch.. too small to fit the fork, but that doesn't worry me as much as getting something to fit in the steerer tube. By the way I would like to set this up threadless but will go with anything that fits.
thanks.
If memory serves me correct, there were a 26.4 and a 27mm fork crown race diameter. I can't say for sure about the steerer tube. I would suggest a call to Merlin to find out for sure. Maybe a call to Chris King might be usefull also. They are the Guru's of headsets. They might have an offering, albeit very expensive. Then again, if your using a Merlin your used to paying for your toys. Good luck.

Tim

Did an inch used to be smaller? I have an original Cambrige, Massachusetts-built Merlin Mountain frame (circa 90's) with the 1" head tube. I can't seem to get ANY headset race to fit in the steerer tube. The races are just 32/nd of an inch too big. I have tried both a new threadless Ritchey, and an old Campy (threaded) headset as well as some other brand, all are one inch and all are a 32nd of an inch too big.
I have built up at least 10 bikes-- old new, both threaded headsets and thread less: Campy, Stronglight, Ritchey, Aheadset, Shimano, Mt bikes and road bikes,but this is just plain weird to me.... Any help would be appreciated. Also the fork race does not fit, by about the same 32nd of an inch.. too small to fit the fork, but that doesn't worry me as much as getting something to fit in the steerer tube. By the way I would like to set this up threadless but will go with anything that fits.
thanks.
Maybe it used the JIS (Japanese Industry Standard) size!? like this one:

http://www.nashbar.com/profile.cfm?category=&subcategory=&brand=5221&sku=11919&storetype=&estoreid=&pagename=

Strange, thought I saw this one earlier... deja vu...

Ahah, here's the duplicate thread on 1" steerer tubes (http://www.bikeforums.net/showthread.php?t=206321).

CAUTION: HACK JOB...

Actually I came across this problem the other day..

The crown/race is bigger then the fork right?

I have a cheap raleigh vector frame I pulled apart (fork destroyed). It has 1 inch threaded head and got a free fork for it. C/O a friend. The fork is nice with columbus drop outs.

I was so excited to put it together.
When I got home i put the 1inch crown on the fork.
It the crown was maybe 1mm (1/32") too big. Sad...
This is because some older forks had a different standard.

My remedy was to use a piece of thin cardboard as a shim.
Call me a hack or what not but it worked!
You could use something metal but whatever. paper compresses nicely.

I simply wrapped a small piece of cardboard around the steer tube then slid the 1inch crown around it.
Then I pressed the crown all the way down. If you have a crown setter, all the better.
After that I just peeled the excess cardboard away. It fits really really snug.

You'll know what to do after that.
I'm going to warn you that this is sort of frowned upon by prestige mechanics.
but its REALLY an inexpensive way to get your bike up and running.

I'd suggest using this method if only if you're in a bind.
IE, can't find the correct headset.

I'd probably use metal or some sort of plastic instead of cardboard next time.
So far this works fine. The fork is solid with no stuttering.

Hope this helps

lymbz is a h4x0r

Yeah, the cardboard will erode over time with water & moisture. You can always use a beer-can for a shim along with some epoxy if you want to make a 27.0mm crown-race fit onto a 26.4mm fork. :)

Hey just to clarify: I am looking for a threadless headset 1" "Japanese Standard" with an accepatble headtube inside diameter range of 29.75 t0 29.9 [As oppsed to the "European Standard" which is bigger...So no shimmying out of this one or I totaly would've had an excuse to buy beer in a can** (I will try that nashbar link above, thanks) Campy, Aheadset and Richtey are all european standard so I am guessing there is a Shimano or Dia-Comp out there which will fit...But who the knows maybe that an Aheadset will work afterall... Also will try Cris King, yes, that might make more sense on this Bling-mobile.
Thanks!

Hello, there are various 1" standards....
The most common were JIS (27 mm crown race) and ISO (26.4mm crown race).
Take your frame and fork to a very reputable bike shop and have them machine both parts to the more common standard ISO. I had this done recently and it cost me $20 for labor.
JIS is no longer widely used (maybe only in Japan these days)....with ISO you have more choices....sealed bearings...etc....

More info...see Sheldon Brown's website....

http://sheldonbrown.com/gloss_ha-i.html#headset