Instructions
1. For a perferct stability, install the frame on a VAR PR-90100 or VAR PR-90200
repair stand.
2. Ensure the right reaming and facing cutter tools, so the selection matches
your frame dimensions. Please refer to the previous page table.
3. Start by machining the headtube lower section. Rotate the frame so the
lower section faces upwards.
4. Place the lower reaming and facing cutter on top of the support and then
slide the assembly through the headtube. The cutter is held on its axle by a
ball-adjustable screw.
Next, install the tapered pilot in the opposite side with the bearing ring, the
compression spring and the push ring.
5. Spray generously and regularly the cutter tool and the machined zone with
VAR CD-77000 cutting fluid, in order to perform a qualitative machining and
preserve your tools’ lifespan.
Pull the push ring up, the spring and the bearing ring so the tapered pilot gets into
position inside the headtube.
6. Rotate the handles in clockwise direction only. If you rotate the handles in a
counterclockwise direction, you are causing damages to your cutting tools.
During the machining, the pressure can be increased by tightening the push ring
progressively. Continue the operation until the cutting tool touches the headtube
surface in order to obtain a perfectly planar surface, without any trace of painting.
The upper and lower headtube surfaces must be rigorously coplanar.
7. Release the spring tension by unthreading the push ring. Then lower the
bearing ring, the spring and the tapered pilot to check the 45° reaming quality and
the headtube surface machining.
If the reaming / machining quality is not satisfying, replace the rings with the pilot
and operate for one or two more rotations.
8. Repeat the operations listed above on the upper section of the headtube,
using the appropriate reaming and facing cutter and the tapered pilot.
The reaming depth being more important on the lower section of the headtube, it
offers an excellent housing to the tapered pilot for a well-alignated machining of the
upper section of the headtube.
9. After machining, thoroughly clean the headtube with a clean cloth and VAR
NL-75300 degreaser in order to remove any remaining used cutting fluid and
metallic shavings.
This will ensure you a perfect assembly, adjustment and functionning headset.
N.B : These instructions also suit non-threaded bottom bracket shells.
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