Originally Posted by
FBinNY
You and I agree that bringing it to a shop is going to be too expensive except for a collector fork.
Where we disagree is cutting vs forming. Often stripped threads are sort of half and half with the mating part (headset in this case) with the thread mashed rather than removed. (if it's actually shaved off it is toast). Filing doesn't flow metal it removes it, but using a steel headset cup as I described earlier might flow enough back to make it workable, whereas cutting more away definitely won't. Since it's a no cost DIY deal, there's little to lose - except the time to scrounge a good condition steel cup.
I also proposed other DIY make do solutions.
OK- yes I have done the same-used a steel headset as a "die"-but usually after I have done a bit of triangular file dressing first-especially to get it started- he says he can't get it back on-meaning can't get it started-
File-useful tool-
Now I have also used a knife to "straighten" threads-no sandpaper-just a thick bladed dull cheapo knife-carefully of course
Sure if he has a relationship with them-they will cut him a deal-but no finicky repair involving threads and a pricy tool is usually $5-it shouldn't be-expensive tool -some expertise-potential to fail in which case customer claims they "broke" his fork-"charged me for nothing" situation-sucky sort of repair since it takes time-but might fail