Drilling vs. hacksaw for galvanized stem
 

Hey all - I've read a lot about how to pull galvanized stems (aluminum stem, steel steerer). I know that I either need to drill out the stem, or hacksaw a couple of lines so that it can be folded in on itself.

My questions are: which is best? Which is safest for my steerer? Which am I least likely to screw up? Which is easiest?

Thanks

Another option is to chemically eat away the aluminum and leave the steel, using lye (and if you do, use serious eye/face protection... you get two eyes per lifetime, maximum).

Hmm... not sure I want to risk that. I have an aluminum frame.

I was considering an ammonia soak, but most of what I've read says it is ineffective.

I'm going to be facing the same dilemma on one of my roadbikes. I think I'll try the hacksaw blade method being very careful, if that fails I'll take the fork to a machine shop and have them drill it out. The fork on this bike is a chrome Columbus that matches my Performance Blue Ridge frame, so I want to keep it.

Right, but there's no risk to your frame. You start by sawing off the stem, removing the fork from the frame, and then leave the steertube soaking in lye for a few days. It'll gradually eat away the piece of the stem that's left in the steertube.

Muriatic acid! Eats aluminum but not steel. Fairly safe... just be careful to open the jug in a windy spot. It's in your swimming pool but in much lower mix ratios. Wear rubber gloves and safety goggles. It's available at Home Depot and other hardware stores. We use it to remove galled aluminum from cylinder walls, and grout or thinset from tiles.

Now if you have someone with a drill press, and can clamp the fork securely
in the vise.
then you can chuck up a 3/4" drill bit and get most of it out.
6/8 out of 7/8"

I just removed a very stuck Al stem from a steel steerer. Ammonia did nothing, the hacksaw was far too tedious and I gave up on that. Tried hammering it out from the bottom but nothing worked until I heated the whole thing with MAPP gas. That broke the seal enough to hammer it out.

Good luck.

Using a hacksaw isn't guaranteed to work and you run the risk of nicking the steer tube. I've used lye before and it does work but that stuff is scary. Be very, very careful if you go that route. The safest and easiest way is also probably the most expensive. Take it to a machine shop with the know-how and tools to do it for you.