Kars 

Thanks dedhed, that is a massive amount of force. I will try simpler things first as I don't even own a come along right now. I am still trying to save the fork for now if possible.

FlMTNdude

Just be careful with it. After a number of tries with other methods, including trying to do 4 vertical cuts inside, I took to it with it clamped in the drill press and a 3/4” bit. Well, the bit caught and now the fork has a couple splits. Needless to say, it wa a visit to the coop and a replacement fork

Kars 

Good point. I recall from the days when I was doing a lot of home machining how aluminum would want to grab onto the toolbit or drills if not all was perfect. Need to have sharp tool , correct rpm etc..

Robert Abrams

Toga Bike Shop in NYC is the place to go to fix Merlin Titanium bikes made in Massachusetts. They distributed these original Merlin Titanium bikes from 1986 on, so they know everything about them. I bought a 1990 Merlin Titanium from Ebay with a horribly loose, unrideable Grease Guard Press Fit Bottom Bracket & a Seized Hideous Stem. No other bike shop in NYC was able to fix this problem, & I was fearful that I had a dead bicycle frame on my hands. Toga was able to rebuild the bottom bracket with new sealed Phil Wood bearings, & can remove any stem seized with Galvanic Fusion between the titanium & aluminum. All for a very reasonable price.

Toga Bike Shop
110 West End Avenue @ 64th Street
NYC, NY 10023

1-212-799-9625
lv@togabikes dot com att: Louis

shipbikes the best & cheapest way to ship a bicycle

If not at or around NYC, strip your bike down & get a used shipping box or frame box from a bicycle shop, tip them $10 or $20
You pay by the size & weight, so a frame box is cheapest to ship.
Remove the wheels, pedals, crank/crank arm, chain, seatpost/saddle.

Vintage Merlin Titanium bikes are great looking, light weight, & should always be saved to ride whenever possible.

Mr. 66

I would clamp the fork to picnic table with the 2x4 and torque to poop out of it.

Robert Abrams

It's not worth the time & effort. Hammering away at a stem with Galvanic Fusion with nothing happening is very humbling.
You soak with aerosol Liquid Wrench overnight first, but reading the label, it's ridiculously carcinogenic, & it splashes up.
I was not wearing a turtleneck, & I had 1 spot that was warm for a day.
I was taking 2 showers a day for 4 days, wondering if I had just given myself cancer in 20 years.
It takes 20 years for environmental induced cancers to show up.
Believe me, I'm a frugal guy, but there are some jobs you do not want to touch, spend a couple of bucks & have the bike mechanic do it.

Crankycrank

Freeze spray inside the aluminum stem can sometimes free things up enough to get it to move. The idea is that the corrosion expands the surface area of the quill and the cold will shrink it slightly. CRC Freeze-Off Super Penetrant 11.5Oz (autozone.com)