Thank you Brian for the full story! I forgot about the slot, now I don't need to ask when that comes up. Your patience to type a lengthy answer appreciated...
Grasshopper humbled!
Jim W.
At 06:58 PM 9/21/2001 -0700, you wrote:
>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