Yep, not giving up hope (and beer/sleep helped).
Progress has been good so far. Here's what I've done: I drilled through the current top headset spacer with a 4mm bit (and in doing so, I drilled out the two prongs). I cut out another top spacer from a spare bit of 6mm carbon sheet I had left over from another project :-) and shaped it out to sit nicely on top of the original.
I also cut a few small dowels from some 4mm stainless rod to pin the carbon spacer to the original top spacer and then to the stem. These are much better!
The next step (and the whole point to this exercise) is now to sand the new carbon spacer/top cap to match the stem and to dowel the two together. Hopefully this is reasonably straightforward. It looks super-neat, will be even better once I put a coat of gloss onto the new top cap!
Cheers, you guys - you cheered me up :-)
Yep, not giving up hope (and beer/sleep helped).
Progress has been good so far. Here's what I've done: I drilled through the current top headset spacer with a 4mm bit (and in doing so, I drilled out the two prongs). I cut out another top spacer from a spare bit of 6mm carbon sheet I had left over from another project :-) and shaped it out to sit nicely on top of the original.
I also cut a few small dowels from some 4mm stainless rod to pin the carbon spacer to the original top spacer and then to the stem. These are much better!
The next step (and the whole point to this exercise) is now to sand the new carbon spacer/top cap to match the stem and to dowel the two together. Hopefully this is reasonably straightforward. It looks super-neat, will be even better once I put a coat of gloss onto the new top cap!