I've read that the most common way of resetting 91mm steel forks for 100mm hubs is to put a lever (pipe) over them and make a gorilla move. Although this undoubtedly works, it would seem that the chances for moving the wheel off-center are fairly steep.

I'm thinking that if I bought a foot of threaded rod and then put washers and nuts inside the fork tips, the gradual stress of the nuts being threaded outward would put more gradual and even stress on both fork legs simultaneously.

If (and it's an admittedly big if) the fork legs were initially brazed with equal security to both sides of the fork crown, then the tensile strength of the legs (being equal) would spread them evenly and thus keep the center of the wheel in the center of the fork.

Is this wishful thinking?

Regardless, how far beyond the desired width must the nuts spread the forks for the new "rest" width to be equal to the desired 101mm?

Finally, there is some hazard in the "gradual spread" method... If the spreader bar pops out of the axle tips of the fork while under tension, some serious kinetic energy is suddenly released. Other than not standing over the forks and wearing safety glasses / face shield, is there any other precaution that can be taken?

Thanks - FH