I just wanted to say thanks for all the various threads on here about making your own headset tools! I needed to change the headset on my rockhopper and had a spare FSA Orbit II XL from a while back but didn't fancy buying all the headset tools...
First of all I needed to remove the old crown race, easily done with a old stanley blade gently tapped in (top tip: wrap the back of the blade in tape for easy handling) then an old screwdriver.
Secondly I needed to remove the old headset. First of all I tried to make one using an old bit of copper pipe I had in the shed. It looked awesome, just like the one you see on wiggle, but shiny copper. I even drilled the back of the slits with a small metal drill to prevent them splitting etc. Slid it into the headset, it expanded with a clear ping and sat perfectly on it. I gave it a few gentle taps with the hammer and all seemed so fine. I then gave it a few **** with the hammer and it all went wrong... Turns out that headsets are stronger than copper pipe. After digging it out I got an old seatpost and made some rough cuts up that to see if it would work. It worked a charm! Looks ugly as but works fine.
The third step was fitting the headset. Using a M12 threaded rod, some bolts and some big washers from B and Q I had something that looked like it would work! The washers were a good £6 but are big enough to cover a cup / headtube and feel very strong, they certainly wont bend. Thankfully I had an old frame with a old headset it (same headset actually) that I practiced removing and replacing with the tool to make sure it went in straight each time. Top tips here are to install one cup at a time and to wrap some tape on the washers to protect the frame. Also I greased the cups before I installed them. There seems to be some dispute here about that but both the headsets I removed were greased and it seems wrong to not grease them to me.
All I need now is new forks - and the money I saved from using the STW forum will help pay for them! The total cost for this lot was about £20 including new hacksaw blades and stanley blades.