Fork shrouds too short

[Russ]

In 2012 I fitted SRM Head stem Taper Roller bearings to my 51 A10 Plunger Frame. They didn't seem to fit properly but thought nothing of it at the time as the frame is still sitting on the work bench. No rush been there since 2009. A couple of weeks ago I decided to investigate further and found on SRM site their documentation now states.

PLEASE READ- rigid and plunger models will have to have the inner corner edge of the frame relieved where the steering stem passes through the area where the outer race cup sits in the frame, there is a sharp corner edge here, and it will need to be chamfered by a Dremmel or similar tool to clear the inner bearing race when it sits in the outer race.

I contacted SRM and they said "Oh Yes" that may not have been known in 2012. I have successfully carried out the modification, although not easy with the outer cups fitted.
Now on Trevor's advice, I checked to see if the fork shrouds still fit. Guess what, they don't. They are about 2mm short of the top yoke. 
Bloody SRM or is it just me. Anyone else had this issue? Any and all suggestions greatly appreciated.
Cheers Russ

[orabanda]

Hi Russ,
Personally, the fork shrouds look like a satisfactory fit.
A couple mm clearance at the top is better than the fork shroud bottoming out under the top piece.

Have the staunchion tubes pulled down enough into the top piece?

Richard

[Russ]

Hi Richard
The forks are not fitted. The steering yoke assembly is just dry fitted, no grease in bearings and not overly tightened.
Just put the shrouds on to see how they fitted.
Russ

[BSA_54A10]

GEt some rubber sheeting in that thickness and cut a par of large washers to take up the space .
If no rubber shops near you cistern washers will fit nicely

[Russ]

Thanks Trevor that's a good idea
Russ

[jhg1958]

I put taper roller bearings on my 1961 A10. It did cause me no end of problems with the new  fork shrouds. I ended up with a bit of cutting and a less than satisfactory job.  It as probably a combination of bearings and new shroud that worked together against me.

I will try and upload some photos tonight.
John

[Rex]

I gave up on taper roller headsets for this very reason....the shrouds no longer fit correctly, and this is on various makes of bike.
On my current A7 the fork shroud top was damaged so I knocked up some little knurled covers on the lathe to hide the resulting gap. They also firmly locate the fork shrouds and stop any rattling.
Maybe this is another way around the problem?

[Russ]

John a photo of yours would be appreciated.  Rex that's an excellent idea, I will investigate that option.
Cheers Russ

[jhg1958]

Not the photos I thought I had but here goes.

First 3 show the bearings proud of the headstock.  The later ones are my struggle  with the new fork shroud.

John