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I can see it working another way. 1" fork.
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I've always wondered why headsets don't use bushings rather than bearings. An Igus bushing would be fine for that purpose
Too much friction in the lower bearing, which has a lot of axial thrust on it. You can ride with a lot of friction (see friction steering "dampers" on some old BMW motorcycles), but it's not fun as you end up thrupenny bitting every curve.
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The only way I can see it working well is to make the headset cups totally external
That's what I meant with "external cups". So, how about this (see below). Would be easier anyway, as they could be made from (easier to machine) aluminium then. When the paint has been cleaned off at the headtube contact surfaces and the ID of the cups are matching the headtube, the assembly would be a press-fit, like a normal cup, even if the headtube isn't perfectly circular the press-fit would probably work well enough.
Any thoughts?
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gbj_tester
jetski
@Brommers
Even in stainless, 0.75mm is bloody thin for something you'll be trying to press fit into the headtube. And 0.05mm is what I'd consider a loose sliding fit rather than a clearance tolerance. The only way I can see it working well is to make the headset cups totally external and then either bond, braze or weld them to the outside of the headtube. With your design I'd classify the headset cups more as bushings than bearing retainers. Mind you, I've always wondered why headsets don't use bushings rather than bearings. An Igus bushing would be fine for that purpose I'd have thought.