Jim,
Yes, it is (almost) that easy. After cutting the steerer off straight using the cheapo steel headset race as a guide, file the cut flat and smooth with a respectable file. Then debur the inside of the tube using the same 6" half round smooth file to make a shallow but nice bevel. Then back off the race and CAREFULLY debur the outside of the cut finishing again in a mild bevel. Done once you remove the race.
However, I've seen far too many butcher jobs when it comes to putting the notch in the steerer for the keyed washer. Ideally, it can be hand filed starting with a 4" round bastard or 2nd cut file making it just a little bit longer than neccessary and tapering the end of the slot into the threads gracefully. Once you have a half roundish slot filed, you can go in with a square needle file and widen the slot and square the edges until your washer slips on and is fairly tight in the slot (in otherwords not too sloppy). You may have to go back with a round needle file to deepen the slot until the washer goes on then go back and square the edges again until everything fits. To final finish the slot, carefully file a slight radius on the wall of the slot where it meets the bottom on both sides to minimize stress. Make sure your stem goes in the proper depth; the stem expander is the slots' worst enemy. Too long of a slot is asking for trouble, make it only as long as neccessary.
Seems like such a simple thing, but every detail matters if you want the frame to be as trouble free as possible during it's lifespan of several generations.
Brian Baylis
La Mesa, CA
>
> CR's:
>
> I know many of you have done this so your advice will be helpful before I
> venture into unknown territory....
>
> I have a new fork to install in an old frame, and the steerer needs to be
> cut down. Any great ways to accomplish this with minimal error?
>
> Right now I just plan to run some headset ring on the thing, cut the tube
> with a hack saw, and then use the ring to smooth out the threads as I run it
> off. Sounds too easy, so there must be some detail I've not thought of...
>
> Your answers, long or short, would be welcome.
>
> Jim Wittstruck, Viking owner
> Lakeville, MN