Hi,

I'm stuck with a headset issue.

I've got a Super Elliott with a TDC headset. The frame has the headset cups incorporated into it i.e. they are brazed onto the head tube rather than interference-fit cups:



The upper internal bearing race is stuffed and I'm having a tough time sourcing a replacement.





I've seen one image on the web of what I need and that was an old ebay ad. A lot of the TDC headsets or 1" headsets I've seen have interference-fit cups and the cups form the bearing race. I've only seen one with seperate bearing races that sit inside the cup (the old ebay ad).

I'm evaluating options:

1. Keep searching for a NOS or original replacement.
2. Have the bearing race I need manufactured (CNC or hobbyist lathe)
3. Cut the Head tube and have it reamed & faced to accept a standard 1 " headset

option one seems an exercise in frustration (unless anyone knows where I can source one).... option two seems unlikey, no fabricators/engineering firms I've contacted have been interested in turning out such a small sample. Three seems like the more likely way to go ... but.... having measured the headtube ID with verniers it looks out of round. Taking two perpindicular measurements of the ID

top of head tube: 29.2 - 29.8mm
bottom of head tube: 29.3 - 29.8mm

ID bearing cups 37mm
OD of bearing race is 36.4mm


So with option three I'm not even sure the out-of-round head tube will take a modern cup ...and i can't measure it but I'm guessing the steel may not be that thick and may not withstand reaming.....

what to do, what to do?