Worn headset. Options for repairing?

[vegansydney]

My Rally has developed an annoying amount of play on the gear selector/clutch side of the headset (see below). Both the throttle and gear tubes are thoroughly greased but the fact that it's almost 40 years and ridden regularly has resulted in it becoming slightly oval in shape.

What are my options for repairing it?
Weld?
Sleeve?
Any other recommendations?

Many thanks!

[H,POOL GADGE]

i,ve just had a throttle bar made of a friend to take a quick action throttle for me px200 a masterpeice and this friend works in an engineering fabrication workshop, thats were you want to be heading, i,d say you have 2 options a sleeve or new throttle and gear change bars(they,d turn the bars on a laythe) it,s not hard for these guys in engineering gadge!

[vegansydney]

Thanks for the heads up

Its a 'German' style model with the bar end indicators so the tubing has both inner and outer sleeves so would be a pain to machine and the tubing is fine, just the headset casting has worn from endless years of use and vibrations. I think sleeving would be my best option, unless someone has any suggestions for welding up the pot metal casting.

I'm all ears if anyone has any other suggestions or advice for fitting the sleeve.

THANKS!

[Fruitjuice]

I remember reading something on the old ScooterBBS about a guy that wanted to drill out the headset and fit thin roller bearings.
Don't know if they ever got round to doing it, and if it worked or not but it sounds feasible...
I would try bronze or possibly urethane bushes personally...
You would have to have them made up but it migth also reduce vibration in the handlebars...