Nice CAD! I know @wzrd builds some pretty cool brazed segmented forks. Hopefully they can comment.
A tip that might be useful is creating miter templates for those segments from this thread:
When I work with tapered head tubes I use Fusion to make miter templates.
This video helped me out: Fusion 360 - Unfolding Sheet Metal Tubing Update - YouTube
I am curious about the choice of the 1 1/8 steerer. I love the classic look, especially with a smaller headtube, but if you are swapping with an Mtb fork, why not just used a tapereded steerer? I am assuming you are using an EC44 lower cup. It looks pretty ugly with a straight 1 1/8 steerer IMO.
From an engineering perspective, the designs make no difference. I think the biggest driver is how you plan on mitering and fixturing the design. If you have to do some sketchy fixturing and mitering, it sucks and could compromise the strength of the joints and allignment.
I have a bad habit of trying to do everything perfectly the first time. It could make sense to go with the easiest method first!
Some Inspiration:
I think Tom makes an amazing fork:
- https://lamarchebikeco.com/store/p/flat-top-fork
- The La Marche Flat Top Fork is Stunning - BIKEPACKING.com
So does Rick Hunter:
- NAHBS Bike: Hunter Cycles Brings Road Plus to Custom Steel - Cyclocross Magazine - Cyclocross and Gravel News, Races, Bikes, Media
- Factory Tour: Hunter Cycles' Santa Cruz Mountain Workshop - Bikerumor
- Hunter Cycles Rigid 29r – John Watson | The Radavist | A group of individuals who share a love of cycling and the outdoors.
If you come up with a design you like, i can create a quick tutorial that shows how I would design and dimension a fork in Fusion. Please don’t make my life too hard 