Help altering a headstock stem

[karoshi]

I'm working through a front end upgrade on my bike, looking to convert a KLR650 using the USD front end from a WR450.

I've got all the WR parts ready to go but I'm coming up empty trying to find a local machining shop to alter the KLR headstock stem to fit the WR triple clamps.

Parts:
https://i.imgur.com/IjU2tYI.jpg
KLR set on the left including an old headstock to test with. WR set on the right.

What I'm aiming to do is use the top and bottom yokes from the WR but retain and alter the original KLR headstock stem so that I can use the original bearings, headstock cap, tensioning nut, and top nut. The KLR stem is thinner than the WR stem, so to do this I think I need to find someone who can:

- Get the stems pressed out of their bottom yokes (I know the KLR stem has a snap ring at the base so it has to be pressed out downwards through the bottom yoke but I'm not sure how the WR yoke/stem goes together)

- Extend the length of the KLR stem by about 8mm (the WR yokes are each ~4mm thicker than the KLR yokes so the stem will need to be made longer in some way to ensure that there's enough thread for the top nut. Doing this would also mean:

- Ensure that the lower bearing can be seated lower on the stem, cut the shoulder for the top bearing further down the stem to allow that bearing to sit lower, cut the thread for the tensioning nut further down the stem to allow it to tighten up properly.

- Make a bushing for the stem to bottom yoke section.

- Make a top-hat bushing to replace the washer that goes under the top nut to take up the extra space in the top yoke hole.

This is all assuming that it's easier to alter the existing KLR stem rather than build one from scratch to fit?

Photo of the stems, KLR on the left, WR on the right:
https://i.imgur.com/MYKXWEA.jpg

I'm based in Birmingham but willing to travel if I can find someone to take this on, or could post the parts out including the old headstock for mocking up with if anyone knows anyone who might take this on?
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Well, I've wrestled with reality for 35 years, Doctor, and I'm happy to state I finally won out over it. - Elwood P. Dowd

[Vincent]

To make it easierer, (not just for me but for any potential machinists), are you able to do a couple of diagrams of the stems with precise dimensions? They don't have to be exactly to scale.
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Space Is Deep

[Vincent]

This similar to what you're doing?

https://advrider.com/index.php?threads/2003-klr650-fork-swap.761310/
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Space Is Deep

[karoshi]

[Vincent]

I'm not recommending it, and he's not cheap, but you may be able to get it done at NK racing in Leicester.

https://www.nkracing.co.uk/
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Space Is Deep

[Pete.]

Normally I would step up and offer machining services but unfortunately I have two stripped-down lathes which are normally fully functioning.

I could press your stems in and out though so long as 10 tons will shift them.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good