Nice work, phattTyre. The weak fork crown seems to be a very common problem, and probably the most common place for chopper failure... I'm trying to figure out some easy ways to do a triple tree configuration, so the fork blades will be supported at the top and the bottom of the headset.

What sort of welding process did you use? We've been doing MIG since it's easy and relatively inexpensive. Someday I'd like to get into TIG, but so far we haven't needed it. (though the all-aluminum full-suspension tall bike isn't going to get finished without a TIG machine that we can borrow..).

peace,
sam