• You should have the stem on before you expand the expander

    'really difficult' is probably overstating it slightly.
    I'm going into the garage right now to go through the process with the stem on before expanding the expander as per your instructions and see how I get on.

    Over time, the headset starts to develop a tiny amount of play. It seems that it's because when I preload the the headset, the stem is so tight on the steerer that its prohibiting the bearing being preloaded correctly - the stem isn't being fully squished down the steerer because of the friction. It always feels fine at the time of fitting but after a few rides a tiny bit of play always comes back.
    It infuriates me. But I admit that I've always been expanding the expander first...

    Any link to details on the swiss cheese number? I wouldn't be against doing something like that.

  • Any link to details on the swiss cheese number?

    I might have a drawing somewhere, but the nut has to be sized to each individual fork so it's really a matter of taking measurements and seeing what works. On the Look 585 which is what that particular one is glued into there's room for the lightening holes to be 6mm, YMMV. Pretty sure the other two plastic forks in the fleet have plain nuts, the drillium is a nice conceit for saving 3g on a weight weenie bike but serves no other purpose. I use Araldite Fusion but any 2-part epoxy will do, the most important thing is surface preparation to get the parts clean and keyed, and let it cure fully (24h) before use.

    I'm a fan of applying 5Nm to the preload screw after tightening the steerer clamp bolts of the stem. #everythingisrubber and a bit of extra tension seems to prevent the stem walking up the steerer.

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