Well I've spoken to Halfords and the guy I spoke to admitted that the star-fangled washer shouldn't have been used so he'd be speaking to the mechanic to find out why he did that and he'd speak to his manager about ordering another fork from Kona. Haven't heard back yet but assuming they do order a new fork, I'd prefer that they just give me the fork so I can get it fitted myself, but no doubt they'll insist on doing the job using the same mechanic who cut the steerer 1.5" too short (so the handlebars are way too low for me) and used the wrong type of fitting, a mistake that ranks up there with putting petrol in a diesel engine.