Threadless headset questions/problems

The threadless fork that I purchased seems OK except that the steerer
tube has a slightly larger diameter (more than 1") section that begins
about 6mm or 1/4" above the fork. The bottom part of the 1" threadless
headset cannot go past this point, thought it overlaps slightly. This
effectively leaves about a 3mm or 1/8" gap between the bottom of the
headset (a sturdy metal ring) and the top of the fork.

It seems logical the the headset should ride directly on top of the
fork.

My questions:

1. Is there some sort of 'secret code' that I needed to match between
the 1" threadless headset and 1" threadless fork?

2. Can I or should I add a couple of spacers between the top of the
fork and bottom of the headset?

On top of all of these problems, my 2 year old son yanked the headset
off the workbench and the top housing cracked on the concrete floor. I
just ordered a new headset. F^&K.

SG, the frustrated one.

PS - Thanks for the help in advance. I can post pictures to the
internet if that would help.

2. Can I or should I add a couple of spacers between the top of the
fork and bottom of the headset?

No, I think what you are calling the bottom of the headset is the fork
crown race. A disc like piece. This piece is press fit on to the
top of the fork. It has to go all the way to the surface it sits on.
Push it as far down as you can. Then put a rubber washer over it to
protect it. Then put the fork in a vice with padding to protect it and
hold it. Then get a piece of 1,1/8 inch diameter pvc tubing and whack it
down gently increasing the whack force. That's what I did, although I'm
a novice.

I think it's better to pay the LBS a few bucks to do a proper headset
installation than to try to do it yourself without the proper tools or
expertise. That assumes, of course, that your LBS has the proper tools and
expertise to do it.

Scott Ghiz wrote:

The threadless fork that I purchased seems OK except that the steerer
tube has a slightly larger diameter (more than 1") section that begins
about 6mm or 1/4" above the fork. The bottom part of the 1" threadless
headset cannot go past this point, thought it overlaps slightly. This
effectively leaves about a 3mm or 1/8" gap between the bottom of the
headset (a sturdy metal ring) and the top of the fork.

It seems logical the the headset should ride directly on top of the
fork.

My questions:

1. Is there some sort of 'secret code' that I needed to match between
the 1" threadless headset and 1" threadless fork?

2. Can I or should I add a couple of spacers between the top of the
fork and bottom of the headset?
-snip-

The lowermost bearing surface ( or bearing seat, in the case
of a cartridge system) should be 26.4mm*, pressed onto a
lip just above the fork crown of matching size. The rest of
the column will be about 25.4mm. Typically a slide hammer is
used to set the lower race. It's best to check the machined
seat diameter with the appropriate Campagnolo 'go-nogo'
gauge before smacking the parts.

Here's a point at which a competent LBS could be very
helpful if there's a mensch in the business near you.

*the older 27.1 format isn't relevant to new forks, AFAIK,
but a measurement might be nice
--
Andrew Muzi
www.yellowjersey.org
Open every day since 1 April, 1971

Thanks for everyone's help! I got the LBS to do the lower race
install for me. Although, fairly scarry sounds were coming from the
backroom while the bike-tech was pounding on my carbon fork :0 BTW, I
loved the idea of getting some PVC pipe that fits over the steerer
tube and then banging away.

Thanks again!