Has anyone ever dremeled their fork dropouts to make the front wheel axel sit deeper into the fork? I'd like to tighten up my front end geometry, and currently am running a straight blade fork. The top of my front wheel (with tire) sits 3/4 of an inch from the apex of the fork, and I'd like to lessen this distance. Structurally, would deepening the fork dropout by 1/4 inch make it completely unsound?

if you like your teeth, that's not the best area to fool around with. it would also be hard to do both side equally. you could buy a shorter fork (lower crown race height).

If you went to a 0-stack headset, you'd probably achieve the same effect, without the sketchiness.

I would not go there and there are not too many things I won't do.

Not only no, but heck no.
A catastrophic failure there would be very, very dangerous.
If you do this, we're all gonna laugh at you, once you get out of the hospital.

Bah. We opened out some dropouts that were just old-fashioned tight and needed to be resized to match the axle we were using. With a hand file. The challenge was getting both sides the same depth: that was *really* hard to do with hand tools. Obviously if you're doing this (1) don't do it on anything with resale value and (2) don't go too close to the brazing and fork end.

I fail to see how this would significantly achieve your aim. Wouldn't changing the fork's rake (even a "straight bladed fork" has rake) change the geometry more than what little room you have to deepen the fork? Kinda like how running bigger tires doesn't really change handling from a geometry perspective.

I was initially thinking that by deepening the fork ends, which in turn would allow the front wheel axel to sit deeper into the fork ends, would in turn bring the rim/tire closer to the down tube. I see where you are coming from however. I'm certainly glad I posted this question before digging in; the professional structural insight has been profound thusfar

Gadzooks! I didn't realize it was you I was replying to... I know you! Don't ruin your bike. If I recall, you don't have the original fork... or aren't using it?

Lets see some pics of your new powdercoat... (have I made you paranoid yet) ?

Whats shakin there filtersweep! Well, you know me, I intended to start this thread as a way to save a couple bucks and continue my tradition of do-it-yourself'edness. This idea may have failed in its hypothetical stages (I still have my teeth), but I"ll have others! crisco anyone?

I did that to my 50yr old English 3-spd to fit a modern quick-release hub, but it was not deepened that much to really make a difference. But like andygates said; make sure you get the fork ends the same depth (I had somewhat of a time with this).

I was just thinking of doing something similiar. I was wanting to take a mm or two out of the forkends to straigten out the geometry of my bike (make it a degree or two steeper).
Ive been thinking about it for a while, and with only taking that little bit off and doing it well, I couldnt really see any danger in it.
The only thing I wouldnt like is that it would make my toptube appear sloped if you looked close enough when really it wouldnt be all that sloped enough to notice at a glance.

If all you want to do is steepen the head angle, the easiest place to start is by shortening your headset stack.

https://www.canecreek.com/67.html takes your headset from 26mm with the S-2 to 8mm with the ZS-2.

From that link...
"and are compatible only with specifically machined head tubes."
...yea, that would rule my frame out then.

Altho my headset is 36.5mm its campy chorus and is smooth as butter, I have no intention of changing it out. Pobably will never file my forks either, just an idea I was toying with. Just like Ill probably never get around to drilling the fork for a brake.

yeah like someone said a few replies up..i filed away at my fork dropout to fit the hub axle and it just took some patience and a careful eye. however, it sounds like you want to do some serious digging and that seems kinda sketchy. i guess just be careful while riding if you go through with it.

Yep, I agree. I'll either just become content with the space between the tire and fork apex (which I highly doubt will happen), or order a fork with shorter arms.