Drill a straight hole through the center of both of
the 2x4 blocks using an 1/8" drill.
On each block, drill a hole 1/2" deep with a
1" drill, using the 1/8" hole as a pilot.
Using a 3/8" drill, enlargen the 1/8" hole
in each of the 2x4 blocks.
Cut a 1" section of wooden dowel.
Put dowel section inside 1" cavity of the blocks.
Using
the 3/8" hole a guide, drill through the wooden
dowel. Use 2" washer on the ends to distribute the
load.
Thread
the 3/8 diameter rod through the dowel and one of the
blocks. Use 1" washer on end of dowel to permit the
assembly to fit inside headset. Note that lower threads
are wrapped with masking tape to protect the headtube
from scratches.
Glue
the dowel inside one of the blocks, use washers and nuts
to clamp dowel in position. Close up of 1" washer.
Note the nut applying a compression load to the dowel.
Using
1/2" drill, enlargen hole in remaining block. Don't
drill through, go about 1" deep. This gives enough
play so that you can fine tune alignment to the headset
before applying pressure.
Thread
rod through block and use remaining washer and nut to
apply clamping force when installing headset. I use a box
end wrench, very little force is required because threads
multiply pressure. Make sure alignment is square.
