Extending threaded steerer tubes

I'm currently building up a touring/commuting bike (think robust and reliable) and have encountered a problem in installing a headset.

I bought a pretty decent frame off ebay, which I then had powder coated at armourtex. The head tube on the frame is approx. 196mm, but the steerer tube is only approx. 227mm, giving me a stack height of 31mm. I can't seem to find any decent threaded headsets with such a short stack height. The only ones I can find are made by Tange, which seem very cheap and pretty crap according to the reviews I've read. Not exactly ideal for reliability.

Though I haven't looked into it fully, I also figure there wouldn't be enough space to use a threadless 1" headset (which have shorter stack heights) and a clap stem.

So I figure my options are to either buy new forks with a longer steerer tube, or to try and extend the steerer tube on my existing forks. The second of these options would be preferable, as it would mean not having to get the new forks srayed to match the rest of the bike. Does anyone have any experience cutting steerer tubes and welding/inserting a spacing tube?

Fortunately I have family friends who are mechanics/engineers, so hopefully someone might be interested in having a go at this for me. Presumably if the steerer tube gets cut at a right angle, and the edges of the insert are also square, it should just be a case of securing it in place and welding it? Finally, the forks are cro-mo, are there any issues welding these?

Cheers,

Matt

might be cheaper to locate a chris king grip-nut.
which will work.

The Tange headsets aren't so bad. I think the Dura Ace ones also have a fairly low stack if you dont use the spacer.

I have one of the Tange ones, seems fine. Open bearings and simple construction. Super low stack height.

Not sealed bearing last forever, but you get your £15s worth.

It's was a Dura Ace headset that unfortunately made me realise I had a problem... Will check out the Chris King Grip Nut though.

Looks like Gripnuts still have a min stack height of 33mm (http://chrisking.com/specs/headsets_all) so no good. Also, original forks are JIS, so have a 27mm crown race ID.

second hand forks are pretty cheap if you wanted one with a longer steerer, alternatively you could face the headtube down and get a few mm back that way, if you braze a new tube on the heat is going to ruin the paint on that fork anyway

I've used the tange falcon headsets before.
Really good. Sealed cartridge bearings and low stack height.
No complaints. And around £15-£20.