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beartrap headset / mk1 gyro

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jstring:
I am restoring my childhood bike which i got back from the paint-shop yesterday.  Like an excited kid, i started bolting bits on last night but I have a bit of a problem.  Originally the bike had an old ACS style rotor / spinner but being as they were rubbish and I quite want my bike to be rideable, not just a museum piece, I have opted to fit an old mk1 oddyssey gyro which is still in period (just) but far superior.

Anyway, I fitted the tioga beartrap headset as usual, dropped on the toothed locking washer followed by the upper gyro tabs but when I went to put on the final locking nut of the headset, it was very clear that there wasn't enough thread on the top of the forks to fit it.  If I leave out the toothed washer, it fits fine.

My question is, has anyone else had this problem?  What is the best way around it?  I am thinking

1.  Run with the beartrap and leave out the washer - but i am worried that it will come loose all the time.
2.  Switch to a standard headset - but i am worried that it will come loose all the time!
3.  Can anyone recommend a headset that does not come loose but which is less bulky?
4.  Has anyone ever ground down the toothed locking washer and / or the gyro tabs (both are pretty thick) to make more room and if so was it successful? Did it make the headset weak / the brakes spongy?
5.  Has anyone got anyother suggestions like tapping tabs into the stem - although I don't really want to molest my beautiful GT stem?!

Many questions I know, and it is a long shot that anyone else has even had such a problem with such a combination of parts (hutch trickstar / tioga beartrap / mk1 gyro) but any suggestions would be welcome.  Many thanks.

Jason

pickle:
Ditch the Gyro altogether and just run with the beartrap headset?

Never did like those Gyro thingies but that's just my oppinion  :daumenhoch:

I've never had an old school headset that didn't come loose!  >:(  but then i've never run with a beartrap, are they good? do they stay tight?

RATTY:
I got an acs rotor on my redline rl, it works just fine. only problem I have is the stem flexes a bit cos it has to be up high.

jstring:
Ooops! Didn't mean to rude about the old rotors!  I ran one for years (and still might end up running one!).  And I can't imagine riding a bike without some sort of rotor / gyro, that's just crazy!

I did fancy a bit of an upgrade though.

And yes, in my experience beartrap headsets were infinitely better than other old school headsets and i have had a few.  Only problem is the forks can wear a bit where the toothed washer engages but even then, the general design is better than any others.

TwoBobRob:
See if you can find an old G.Sport 1" headset locking ring.  Its a nice little nugget that will lock your headset down and replace your top gyro plate at the same time.  I ran that with a beartrap for years, no worries.

I may still have my one, I'm not sure.  i'll see if I can dig it out if you're interested, let me know  :)

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