You might find you have come across cross standards issue? As the frame could be Ahead etc types yes the Yanks have a lot of changes for sake of changes! and Ahead frame headstocks are bigger than the old style threaded headsets. 1 inch.1,1/8".1,1/4"
https://www.parktool.com/en-int/blog/repair-help/headset-standards
Its a modern bike. the headset and headtube sizes are for want of a better term a ***** joke.
Bike arrived with a damaged fork. (From CRC, which is now closed down)
Removed fork.
Fork steerer is 1 1/8"
So normally where the crown race sits, it should be for 1 1/8"(actually 30mm standard size crown race.
Not so on this fork. Where the crown race sits it has a wide/thick section bringing the crown race to 1 1/4" size.
Lower bearing headset cup is 1 1/4"
Remove lower bearing cup - measure headtube size for replacement
Measures 1 1/2"
So the headtube is tapered size -
Tapered is normal these days. my sus Emtb is is tapered, my sus mtb is tapered, and ive a number of forks, Fox factory, pike,lyric are tapered, but to long travel for this bike
What is causing the issue is its an 1 1/8" fork, going into a 1 1/2" headtube, thats been reduced to fit a 1 1/4" headset.
1 1/2" is a standard size. But theres more than a single 1 1/2" sizing. We can have 1 1/2" that is 49.7mm(known as a true 1 1/2", but also under the 1 1/2" heading we can have 55.9mm
We have traditional standard, integral, semi-integrated and even in a 1 1/2" lower headtube can all be slightly different sizes. Its all very confusing these days :lol:
SO.
To make it work, i buy a fork with 1 1/8" steerer, the standard 1 1/8" crown race, and to fit to the frame a stepdown lower headtube bearing cup(Hope type 'D') that is 49.7mm outer diameter, for a 1 1/2" headtube that should have fitted without any issue.
Only its loose, and its lose because the manufacturers of this type of bike are complete tw**s and decided to do everything on the cheap.
So, to take up that difference i need to wrap the lower cup where it goes into the frame with something to take up the difference.
I've not got the best of digital calipers, so readings arent as accurate as it goes, but from the known sizes i can guess what they are supposed to be.
I basically need a tape i can initially wrap round, and add more til the fit is as tight as it should be. I've access to a proper headset press, and have fitted a number so know what Im doing on that account.
I admit this was a bit of an impulse buy, £500 for what is a £1500 commuter type ebike, which is something i need as my other emtb is close to £6k, and i want something i can take into the city and leave there while i go shopping and not worry about it as you would if it were a £6k affair.
It's been a bloody headache, not helped by the manufacturer 4r5ing about with the sizes and fittings 5to save money. But it is what it is and im sure i can eventually sort it.
Just need to find a good quality alloy tape what isnt basically tissue paper.
'Ahead', 'threaded'
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if only it were that simple these days
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