So I took on this repair, and actually turned out pretty well. Fortunately, the owner is a fabricator himself and did a great job removing/cleaning the tubes beforehand, so made my job that much easier. Essentially an entire new front triangle with a much beefier headtube. Hopefully he keeps it off the Rampage course this time :) just kidding.
Pretty nice fit up. Pretty much based on the original manufacturer's specs.
Went with a much beefier 44mm headtube.
This was perhaps the toughest part of the repair. The seat tube at the BB shell was ovalized a bit, but luckily just a tad over one of the hole saw sizes. Pretty much pulled back in the miter, and with a few strokes of the file, it fit!
Again, everything went pretty smooth!
