Originally Posted by
BCRider
Even if it doesn't actually fail and fall out and make you eat pavement it will still have a couple of problems. Being smaller the quill will flex more easily and this will allow the epoxy at the joint to fail. Since part or all of your upper headset components will be supported by the bit above the joint it's going to allow the bearings to flex out of alignment and wear away at parts of the cup and cone far more quickly than normal. On top of that there's a good chance that the levering action of the flexing will make the glued portions creep and you'll continually be fighting with loosening headset issues.
That's what I was mainly wondering about. Not sure what the forces would be on that part. If it did fail I don't think it would be completely and immediately catastrophic. The stem would still be stuck in the fork and on this bike it would be set low. It was just an idea out of frustration for a tiny bit too short fork. No way I would try to sell it to anyone or just get on it and go down a big hill. Thanks for the feedback.