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My Inbred commuter has a slightly flared head tube. Has done for a while but the lower cup is very rattly/creaky when steering or braking. Even just looking at it it creaks!
I was wondering if there was a headset like the Chris King steelset with deeper cups to shove inside the headtube?(but LOTS cheaper)
I have one of these on my Nicolai. No idea if it will solve your problem but highly recommended.
http://www.balfa.co.uk/acros-ah-07-deep-cup-headset
This is cheap and cheerful and looks like it'll do the job for commuting:
http://www.chainreactioncycles.com/Models.aspx?ModelID=24987
You could try bonding in the bottom cup with Araldite or J-B Weld?
Cheers chaps. That Crank Bros one is winning on price. I'll wang it in with a bit of glue and it'll be fine.
I've just remembered the previous headset was shimmed out with a piece of beer can at one point! Booooodge.
More beer can sounds like the way to go then. 🙂
Might go for baked bean tin this time and a BIGGER hammer.