These forks are kinda rare. I only found one set on eBay that was in good shape and complete. There are probably more, but they either came with 3/4 handlebar clamps or 7/8. I think most of the NOS ones were set up for 3/4 handlebars. It’s not impossible to get 7/8 bars to fit. Others have also had this issue, so I’m going to do a search and see what their solutions were.
Id assume you can get new clamps too if you need.
I've used small self tapping screws through clamps in a few locations on devices on my handlebars.
That’s like saying a 2mm bolt hole pattern difference should line up. It won’t. Tolerances are a thing.
The top tree is aluminum and the top handlebar clamp is aluminum. If I could find a direct replacement made of steel, I would do that, but I don’t know if the geometry would match up and since most bikes don’t even list fork geometry, even if I measured mine I have no idea how to search for a replacement that would match.
You're probably not going to want to hear this. I'd take thick 1" ID steel tubing cut it in half and and squeeze it down to fit 7/8" OD tubing. Then I'd weld that to a couple pieces of 1/4" flat plate. After that the flat plate could be cut out to match the original aluminum plate. It'll be a simple matter of putting matching bolt holes in the part you just made. Finally all you'd have to do is clean and polish the part.
