My Windsor Kniight (new in Feb) has a brinnelled head set, so I bought a new one.

I have installed and removed headsets in the past and always used a big drift punch to remove cups by hitting down on the inside of the head tube . I can't budge the cups on this aluminum frame, even using a two pound club hammer. Even tried using a pipe wrench since the headset was toast anyway. Didn't think it would work and it didn't.

Can anybody tell me if there are systematic problems that have evolved in the last 10 years? Would I expect this type of problem with any newer frame?

I'm sure I'll take it to the LBS and maybe they can get it out with the proper tools and better support on the frame, but this isn't rocket science. It comes under the heading of "don't force it, get a bigger hammer". I did and thought it was as big as I should need.