I got a new bmx frame, my old one was flatland and looked funny on all my street parts.Anyway, i tried putting my old fork into the new frame, along with everything else to see if it would even fit. When i put in the fork, obviously it fit since its standard 1-1/8. However,once i tried pushing the fork all the way up, the bearings at the bottom wouldn't allow the fork to go any higher, they seem to big for the frame. i took the bearings out and tried the fork alone, the fork fits fine and looks like there is still space for bearings, but much smaller bearings. is there such a thing? smaller bearings? i thought it was all standard.. if there are i will simply go to the bike shop and buy these bearings.
It shouldn't be too thick, I've framed things thicker than a puzzle. There is this sealer you can get a a craft store to put on the puzzle so the pieces don't come apart, that's if you don't mind it being together forever. I like to use swiss clips for frameless frames (kind of an oxymoron).
In the old days they just put grease, and roller bearings until it was full, then reassemble.Depends on the races.
In the place you put the forks you’ll see cones at the ends of both the holes, perhaps these cones are too big for you bearings. For eg; imperial cones forks to new metric cones forks, Bike companies would probably do this so you can’t mix their bike parts with other bike parts which in resalting you to buy the parts off them. I know it can’t be the bearings because bike bearings are universal and as such make them all the same (rather than crank and rim cone bearings which are a lot bigger and smaller). My verdict is to take of the old cones on you old bike and put them on your new bike.P.S. the threads on your forks might not be long enough anyway