So you're trying to convert a 1-1/8" threaded headset to be threadless by hand-filing the threads out of the adjusting nut?
Several reactions:
- I hope you have a really, really good reason for doing that vs. the seemingly quick/easy/safe/cheap route of just buying a new headset.
- It will really only work on certain headsets -- as many (most?) models will have no hope of really being able to consistently pre-load the bearings in that configuration.
- Do you really mean HAND filing off the threads? That seems horribly tedious and your hope of having a nice round surface when you're done are approximately ZERO.
Sorry to be so negative. Perhaps some of the "engineers" on here might give you more encouragement.