Headset installation without proper tools

ive installed my headset a number of times, by hitting it home with the rubber coated handle of a hammer. it has always worked, but it chips and damages my bad quality paint job.

ive just had a nice looking paintjob, but its still not great quality paint. so id like to avoid this happening if possible.

dont really want to buy a proper press, and making one of those DIY presses looks like alot of effort.

anyone got any tips on ways to do this better?

soft wood (pine) + hammer.

does the wood damped the impact?

i think im gonna put masking tape around the headtube as well this time in hope that itl hold the paint from chipping.

i used 2 copies of the yellow pages and a hammer.
line cup up. put yellow pages #1 on floor. put frame on top. put yellow pages #2 over the top of the cup to hammer in. hammer. gently. but firmly. and with purpose.

Long bolt and nut. Preferably threaded along it's whole length, preferably fine thread. Thick steel washers. Cup of tea

I know you said you don't want to make a press, but it really is a great way to install the headset without using a correct press.

If you search there are several threads on this, I wrote a post in one with links to the correct bits to get from Wickes.

See here.

As above.
Made one last week to install new record headset, no problems.
Cost £4.

my dad gave me a nice toolbox he stole from work today, so i think ill make a press so i have another tool to put in it.

ewoo- i think i get the general idea of how it works, but do you have a picture of the completed press just to satisfy my curiosity? do you press both cups in at the same time, or do the washers on the side without the cup press against the bare headtube? did you use anything on the washers to protect the headtube/cup?

DIY homemade headset press that does it everytime....get an 18" length of stud bolt from a hardware shop plus two 17mm nuts and two 3/4" steel washers (should all be around £5.00) then press the upper and lower headset cups into position and as straight as poss. screw on one nut and washer a short way in on the end of the stud bolt and then offer into the headtube, now screw on the other nut and washer on the bit of stud that protrudes at the other end of the headtube and do both nuts up fingertight....making sure the cups are still seated straight now proceed to tighten each nut evenly with a suitable 17mm spanner and continue tightening until they press the cups home nice and straight, much better than hammering as that can damage the cup edges

[FONT=Calibri][SIZE=3]Hello,[/SIZE][/FONT]
[FONT=Calibri][SIZE=3]Got a headset press in B’ton.[/SIZE][/FONT]
[FONT=Calibri][SIZE=3]Jerome[/SIZE][/FONT]

+1 on the build your tool thing.

I've got a set of attachments for my drill for cutting discs out of wood. This is handy as it lets you make wood discs which will fit snug inside the lips of the cups and center them. I found this to be vital otherwise the headset will not go in straight.

Funny pics attached.

The first of the tool, showing (from centre out) wooden centering discs, wooden pressing discs, washers, bolts, and the threaded bar itsself.

The second showing the headset (yellow) and headtube (green).

I also was lucky enough to find a steel pipe at work, with an internal diameter just over 1" which was useful to bang home the fork race. Bloody stressful though as its a meter long and bloody heavy.

2 Attachments

Nobody want to look at my pretty pictures?
bloody cheek ;)

Very useful info and great pictures Smallfurry. Thanks

Been trying threaded bar to replace headset cups on my beater MTB hybrid conversion. Can't get them to go in straight, so ended up whacking them in with a Rubber Mallet. There's a very small gap between both and the headtube now - but they're in straighter than with the threaded bar method and no amount of whacking or threading will get them to go any further. I'd used 3 washers on each end of the bar and they've just bent rather than moving the cups anywhere.

Had also tried the dumbell method, but my cheap argos dumbells just aren't up to the job either. YouTube- MtnBikeRiders.com Tech Tip

Reckon I'm gonna buy a headset press for the future, proper tools ftw.

ride it like that if they move tighten it up

A rubber mallet may bounce more than required. I just use a block of wood and a large metal mallett and they go in no problem. Do take a fair few whacks but the wood always protects the cups. I use a work bench to rest the other side of headtube on which is also made of wood.

Cheers... will try one or both of those - ta.

Yeah. Same as Kerley. No probs.

Bit late now, but I like to leave the cups in the freezer over night, and the frame near a radiator. This really helps.

i use a wooden mallet then just bash it the fuck in.

Agree ^ Wood + Hammer = Done (of course this can crack the frame if you're unlucky!)

get a bit of 10mm threaded rod,14mm M10 nuts and 2 square plate washers from any good hardware/ toolshop cost well under a fiver

ride it like that if they move tighten it up

not really the best idea as cups that are not fully inserted or poorly installed headsets have the potential to ovalise your headtube and then you're fucked.

cost of new frame > cost of getting the proper tool or paying a mechanic to do it

Use the home made threaded bar opress, as described, but always clean out the inside of the head tube (I use emery cloth) then very lightly grease. Pop cups in the freezer for an hour or so before you put them in. Works for me, always clean and straight first time.

never thought about the temperature changes. Explains why the headset I put in a couple of days ago took a bit more aggression than usual as the frame had been in the 0 degree garage but the cups in the 20 degree house!
I find it helps if I put a picture of my wife on the block of wood (come back Les Dawson)