Join Date: Feb 2004
Location: St Peters, Missouri
Bikes: Rans Rockst (Retro rocket) Rans Enduro Sport (Retro racket) Catrike 559, Merin Bear Valley (beater bike).
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Is the threaded part of the fork chrome plated? If it is, the dies that an LBS is likely to have won't cut clean new threads.
One possibility, if you don't need too much, is to use headset with a lower stack height. Tange Passage headsets, for examply, have only a 30.3mm stack height.