JDFlow

I knocked out my old cups with a metal file and a hammer. I caught the edge of the cup with the blunt end of the file and hit the other end pretty hard with a hammer. Once I saw some progress on the side of the cup I was pounding on I moved to the other side and repeated the procedure. I knocked both sides of the cup out an equal distance to prevent "ovaling" my head tube. Then I greased the inner ring (the part that goes into the head tube) of my cups and started them into the head tube with a rubber mallet, then clamped them in the rest of the way using this bad boy I assembled at Ace Hardware for $3.80 (pic below).

https://picasaweb.google.com/lh/photo/YzbPCDJQczCrPHeLZICcwQ?feat=directlink

reptilezs

super

BCRider

Instead of a file I'd suggest a long tapered pin punch or even just a length of 1/2 inch steel rod. A file is typically glass hard and quite brittle. If by some chance you hit it wrong or it just decides that it has had enough and it shatters in the area you're holding it the razor sharp edges will do a number on your hand.

I use the same method, other than a pin punch instead of a file, and walk the cups out. But I give only one tap to each side. This walks the cup out in steps about the thickness of a piece of paper at first but it further avoids any ovalizing stress for the head tube. As it comes out further I lighten up on the taps to keep it moving in very small steps. If I can SEE an angle then it's too much. It takes me typically 30 to 40 times back and forth to remove a cup this way but I'm certain it didn't create any ovalizing.

JDFlow

Good advice, I had no idea. Even though my file has a large plastic handle that would probably prevent me from getting cut I still don't want to shatter it. I've also heard a wooden dowel is a good punch for the job.

roadfix

My headset press cost me $5 about 15 years ago.

HillRider

BCRider is quite correct. A file is very hard and equally brittle and it won't bend, it will shatter if hit hard enough.

A wooden dowel probably won't work either as it is too soft. The ideal tool is a brass or aluminum small diameter rod long enough to reach the cups through the headtube and driven by a medium weight hammer.

Actually, now that I think of it, the ideal tool is a "rocket tool" specifiably made for headset cup removal but a soft metal punch is a good second choice.

BCRider

Oh SURE! Go and play the ol' "right tool for the right job" card! PARTY POOPER! ! ! ! !

WillJL

I'm awarding 10 points to roadfix for his excellent headset press. Looks just like mine!!! Will someone please remind me why spending for a fancier one would be a better option?

cs1

Bravo on the headset press. No need to buy a tool you can make just as good. The file for removal is crazy though. As mentioned you're going to screw up the cups and maybe injure yourself if the file shatters. Better to buy the proper tool. Nashbar has the for a whopping $18 on sale with another 20% off. https://www.nashbar.com/bikes/Product...2_10000_200498

Wordbiker

Speed.