I had a 2004 Fuji Newest frame warranty-replaced with an '05 Newest frame. Among the changes was a switch from the recessed headset style to the... umm... non-recessed style. The new headset (pressed into the head tube, it looks like) has the following issues:

- The new frame didn't include the "convex hollow alloy 25mm spacer." Because the old frame had the oversized head tube for the recessed headset, the OD of the old convex spacer is too large, and seems like it would funnel splashed water into the headset. However, it seems like leaving the spacer off would just invite water/contaminants in from the top (since the OD of the headset is larger than the OD of the headset spacers). Where can I find a spacer like that?

- I have an Alpha Q EX fork. The crown race that's currently on it is too short -- the wide, flat, lower part of the race butts against the outer, non-rotating part of the lower headset cup. However, the crown race on my old fork (damaged in shipment, hence the Alpha Q) seems to fit perfectly. Would it be possible for an LBS to remove the too-short one and replace it with the one from my old fork? Could I do this myself? (I don't have any sort of headset-specific tools, though I have enough general tools available that I can probably rig something up if I'm sure I won't hurt anything).

Please, please help if you have any suggestions for either of these questions; I posted on the Bike Mechanic forum 20 hours ago with no responses, so I'm hoping it's just that they're more roadie-oriented questions.

I'm not sure if this is what you're referring to or not but if the head tube is made to receive an integrated (cupless) headset then I'm not sure if it is a good idea to use a standard headset with cups. Th etop and bottom of the head tube are beveled to match the bevel of the bearing cartridge. You also need to set a fork crown race at he base of the steering tube.

No; the new frame has an accompanying new headset. The crown race from my original, damaged fork fits the new headset perfectly, but the one on my replacement fork does not -- it's too short. I'm wondering if I can pull the crown race from the original fork and stick it on the replacement fork.

The new headset should have included a "matched" crown race for the fork.

There are tools to remove the crown race and also to seat the crown race. Although I have removed a few "carefully" using a flat faced punch (I've read of some folks using a screw driver). To seat the crown race I use a PVC pipe with or without a copper or bronze pipe fitting; which may be found at a hardware store.

That's a clever DIY tool. I'll have to try that next time

I cant give you a good answer to your question however I have a prefference for the older pressed in cup type of headsets rather then the newer integrated type. There less fussy to adjust properly. I'd go to your LBS anyway. It will be worth the hassle when you get it sorted out.

Regards, Anthony