Headset dilemma

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Hi all,

First, this is my first bike project, so pardon my abundant inexperience. I’m trying to bring an early ‘60s Murray Sonic Flyer back to life. The bike followed me home from a salvage yard a few weeks ago. Here is the problem, I need a new headset but the bike has a 1.5 in I.D. head tube and a 1 in threaded fork. Apparently nobody makes that headset anymore. I’ve researched head tube reducers/ adapters/shims but all I find reduce to 1 1/8 fork size. I see lots of beautifully done bikes on this forum of the same vintage. How is everyone else solving this problem? Uploaded a picture of the bike as I found it.
 
One other way i use here in Europe, where even that headset from Amazon is not available, is getting 1-1/8 headset (optionally reduction headset with 34mm cups for 1 inch fork or the aluminium adapters you mentioned) and cutting it on a lathe. You need to remove 1,5mm to make it 32,5 from 34, they are always strong enough to survive that. If you are hardcore enough, you can even do it without a lathe, just put the cup on the rubber piece on a bolt with two nuts, tighten them so the rubber expands and holds the cup and then put it into your drill. Grind it over a file, just don't forget to let it cool time to time so the rubber won't melt :D
 
One other way i use here in Europe, where even that headset from Amazon is not available, is getting 1-1/8 headset (optionally reduction headset with 34mm cups for 1 inch fork or the aluminium adapters you mentioned) and cutting it on a lathe. You need to remove 1,5mm to make it 32,5 from 34, they are always strong enough to survive that. If you are hardcore enough, you can even do it without a lathe, just put the cup on the rubber piece on a bolt with two nuts, tighten them so the rubber expands and holds the cup and then put it into your drill. Grind it over a file, just don't forget to let it cool time to time so the rubber won't melt :D
Stranger
Sanding, painting and bolting on new parts are the total of my abilities. But you info is helpful anyway. Thanks.
 
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Maybe the 1+1/2" measurement was the Outside diameter - or time for new digital caliper (micrometer).
https://www.ebay.com/itm/150MM-6inc...iper-Gauge-Micrometer-Ruler-Tool/401541751221
[32.5 mm is about 1.28" = 1+1/4 plus 30 thousandths/inch].

Phil,

Glad you asked that question. As previously noted I am definitely a newbie. I was measuring the I.D. but I read the calipers incorrectly. The I.D. is 34mm or 1 + 5/16, a little over 1 1/4. Notice that I’m using a non-digital caliper (too cheap for the digital variety). So it does look like I can use the headset mentioned above might work. If nothing else I am learning a lot on this project. Thanks!
 
View attachment 85041

Phil,

Glad you asked that question. As previously noted I am definitely a newbie. I was measuring the I.D. but I read the calipers incorrectly. The I.D. is 34mm or 1 + 5/16, a little over 1 1/4. Notice that I’m using a non-digital caliper (too cheap for the digital variety). So it does look like I can use the headset mentioned above might work. If nothing else I am learning a lot on this project. Thanks!
34mm is standard 1-1/8 headset size. You may use modern reduction headsets then to run 1" forks there.
 
I was thinking of my Murray frame, I vaguely recall reinforcement shims inside the bottom bracket and head tube, but maybe I am remembering the wrong frame; what if they stopped using such reinforcements(?).
My rule with measurements is measure ten times and also write down what I measured, because they seem to grow or shrink over time. And then there are those odd-ball headsets, like the ~33 mm Worksmans, and the 35 mm Ross's. Sometimes the Wald economy headsets, with the 3 nubs are a way to go.

Electronic calipers are nice, but when the batteries wear down, seems like its cheaper to just get a whole new caliper.
 
I use a lot of the Wald 3 nib headsets as mentioned above on old one inch headsets. They often won't fit but by using a Dremel Tool and a Dremel carbide rotary file I can usually get them to fit by grinding of the nibs. I keep a bunch of these on hand. Cheap, but OK for average riding, not good for a klunker. Some old non Schwinn one inch headset bikes require a Schwinn headset, or an old school BMX headset. The top and bottom diameters are not the same. It can be frustrating. I have on old 1936 Rat that I could not find a headset or bottom bracket to fit. I tightened up everything snug and tack welded the 4 new cups to the frame. Works perfectly. Let the next guy curse the idiot that did that Youper hack I say.
 

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