I installed an FSA Orbit headset onto the Surly 1x1 just this weekend. Whole process took me about an hour.

Used the threaded rod and big arse washers routine for the bottom cup. Happen to have a brass pipe fitting kicking about that I used to actually push against the cup. Should note here that the particular Orbit headset was a cartridge bearing setup.

Used a large deadblow hammer and a block of wood on the top cup. Followed that up with the threaded rod routine again to really seat both cups.

Crown race was a split ring assembly, a three year old could do that one.

Installed the fork and stem without using the star-fangle. Just pressed down on the stem to the point I could tighten things up. Rode about for a while till I was satisified with the stackup, took some measurements, disassembled and cut the tube.

Cutting the tube was accomplished with hacksaw and pipe clamp. Turned out slightly out of square (maybe 0.02"), this could have been alleviated by rotating the fork in the vise. Cleaned it up with a angle grinder.

Installed the star nut by threading it onto a longer bolt and smacking it into the tube with the aforemention deadblow hammer. The longer bolt gave me the leverage to pull the nut back to vertical.