All-
A few months ago I modeled a dummy headset to be 3D printed. I've refined the design a bit and , and I really like the results.
ABK1001 NoHeadSet assy.jpg
I've put the assembly up for sale on Shapeways, and I'd love it if you all would buy a set and let me know what you think. I'd eventually like to get these mass produced in nylon or aluminum, but for now 3D printing is way more economical. The set is about $30, which should be worth it for most of you no matter *how* quick you are with a lathe :)
The headset is two parts. The top half has two 3.3mm holes "drilled" in it; they need to be tapped M4 in order to make the assembly really work well. I would recommend using brass tipped set screws for aluminum or steel steerers, and nylon tipped set screws for carbon fiber. You can also experiment with thumb screws or plain old socket cap screws if you like.
A note about how Shapeways works: I designed these parts and Shapeways 3D prints (SLA) them and ships them directly to you. All payment, order tracking, etc happens through them, and I never see the physical parts at all. They usually ship within two weeks.
If you're in the market for a dummy headset, please try mine out and let me know what you think. It's still a work in progress, but I suspect that it'll be useful for a lot of builders and shops.
Spencer
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