Hi,
I'd like to present my project of Chris King NoThreadSet.
Browsing the Polish light-bike forum intrigued me Adamello's project and I decided to do something with my headset.

The first plan was to perform the GripLock cap with cone in one piece, exactly like original CK, but made of carbon fiber.
I intended to do the GripLock of carbon spacer, but it has a larger inner diameter than the original CK item, and I was afraid of backlash.
The second thing I feared, was that the carbon cone would be hard enough to not knead.
Finally I decided to separated cone of cap and made cone of alloy. Indeed I made a prototype of carbon cone, 0,4g lighter than alloy, but I didn't decide to use it.
The remaining cap's part was taken of 1mm carbon plate.

The second element of headset that has been changed, was baseplate. I designed a thinner and lighter version and made of alloy.

The final result on a scale give 82g. 16,7g less than the oryginal CK set.

Set ridden since the spring and works great.

I think you could make a side business selling your CK alloy baseplate in a 1.5" size. The new CK tapered headsets only have available steel baseplates in those sizes (at least for the 1" or 1.125" they have a Ti version that weighs less). I don't remember the weight on the one I had in hand, but I think it was around 40g or something like that. An alloy one would represent a big weight saving! (I went with the Cane Creek alternative because it weighs 40g less... mostly because they use an alloy baseplate)

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Enjoying my Funk