Originally Posted by
Standalone
Nice graphic.
I just did the opposite (susp. to rigid) and found that the steerer tube on the rigid had the same lip. The crown race from my new headset did not fit on it well, and actually split when I put it on. Everything else seemed to go together ok, and since it's a cartridge headset, I figured it would last a decent amount of time. Since your option is to seek out a different headset or crown race, why not run it as is until it fails. It shouldn't be a catastrophic or dangerous failure when it goes.
Are you sure it wasn't split before you started? Lots of cartridge style headsets use a split ring because it's not really a bearing race. The race is integrated with the cartridge.
Also, if it was 1", are you sure you had the ISO/ JIS thing right?