hey all,
forgive please if this topic is already covered. i just didn't get anywhere with a forum search

i have a used mtb frame coming my way at some point. the head tube is 4.5" long and 1" diameter. my conundrum for the past several weeks has been trying to source a 1" steer tube to put an old marzocchi suspension fork on it when it does arrive. fyi, i have the fork, and currently it has a 1 1/8" steerer that bolts/clamps into the crown.

now, i've not had any luck sourcing the 1" tube at a price i'm willing to pay.....until today. the deal is it's a trade of identical fork crowns with a member on another forum. but, the kicker is his proposed crown has a steer tube of only 5 1/8" in length. ideally i'd need atleast 5 3/8" minimum with my "regular" stack headset. so, according to my measurements, 5 1/8" would only leave me enough thread just to get the top threaded bearing race on, but not the top lock nut. i do have a new short stack headset that might do the trick, but what about also simply cutting some of the head tube down to swing things even more to my advantage? i'm not concern with it throwing the geometry off as the frame is not suspension corrected, anyway. furthermore, the fork travel is only 60mm and shaving the head tube a tad (on the bottom end) couldn't hurt as far as geo is concerned. and, besides, i think a few mm's top and bottom would get me where it needs to be.

so, short of taking this to a frame builder ($$$!!), is there a good way for a rather tool skilled guy to do this at home with good shop tools? what tools would i need?

fyi, paint's not a concern as i may repaint, anyway.

thanks!