Will a DC fork (03' Sherman Slider) that specifies the minimum HT length be 125mm fit on my 02' Stinky that has a 120mm HT?

Also has any one safely installed a Chris King steel headset on the 02' Stinky?

Tax returns are coming in and I have up-grade-itis.

Double Crown forks will fit on that bike no problem.

The Chris King Steelset, on the other hand, will not. It's got those deeper cups, which aren't necessary in the Kona head tubes, as they already ahve material added on the inside. That material will not allow that headset to be installed.

I know that the HT was reamed out to fit shorter cup lengths, but even if I ream it out will it not fit in the head tube?

Because of the reasons explained with the reaming that'll be necessary. If you go ahead with a normal King headset with the Sherman, it should be fine. I rode with someone last weekend who, in the past, had ovalized his headtube using a Boxxer on his '02 Stinky, but he admitted to having a sh*tty Cane Creek headset on and said he thought it was somewhat loose before he crashed. I think the key takeaway is to put a nice King or FSA on your bike and make sure that it's tight!

Don't know much about the Sherman Slider (you should contact Answer), but it says the following:

Use size Small with headtube lengths less than 145mm.
Use size Large with headtube lengths 145mm or longer.

Cheers,
EB

P.S. You can get the '03 Slider from Green Mt. Sports for ridiculously cheap right now!
http://www.greenfishsports.com/index.asp?PageAction=VIEWPROD&ProdID=378