adlai

But one part won't fit. Pictures...



As you can see, one cup doesn't go down the entire way. I've tried pounding it with a pipe overlaying the fork -- no luck. And anyways, if you look at it touching the cup and ball bearings, it seems that it juts out just a bit meaning that the fork would not be flush with the frame.

Get a different size headset or shimmy the fork down some?

KBentley57

what tool are you using to install the cups / crown race? it takes a good bit of force to get everything seated tightly. The all-thread/washer/nut and pvc pipe methods work well enough on the cheap.

Andrew R Stewart 

Are you sure the headset matches the frame/fork dimensions? Andy.

adlai

both are 1 1/8

adlai

I got the little crown on the fork, but still there's a gap between it and the frame.



I got this headset

Sunlite Steel Headset, Threadless - 1-1/8", Black

Starting to think I might need a different headset all together.

Andrew R Stewart 

The above photo looks to have the lower stack's bearing in upside down. Or maybe the seal was placed in before the bearing. Either way the cup and crown race don't nestle together as they should. Were the two frame cups of the same depth? maybe the upper cup, which is often of a smaller depth, is installed in the head tube's bottom. Andy.

adlai

That is possible, but when I put the fork in the other one, it is still short.

I'm wondering if I got like a BMX part by accident. Should it matter?

hueyhoolihan

if it works, it works. i've seen a lot of posts recently where owners are upset that their headsets show a millimeter gap at the top or the bottom. for the most part, it's turned out to be cosmetic. occasionally it's an installation problem.

Andrew R Stewart 

While I've seen it happed before, it's doubtful that the headset box conatned missmatched parts. That usually happens during trial installs when a few headsets are on the work bench at the same time. Evidence of prior trial or repackaging is often a sign of this possibility. But most mechanics try REALLY hard to not mix up parts like this. And if the headset was purchased on line I doubt it was ever opened before it was shipped. Even still BMX headsets don't have a big gap between their elements. Is it possible that a seal is missing? Does the function of the headset seem proper? As in spin smoothly and is able to be adjusted to have no play and still spin? Andy.

adlai

It is possible that a part is missing.

I'm worried more about water/mud getting in there with the gap so big.

Andrew R Stewart 

Last post- Dirt, water and grime will get into there regardless. Tight fittings just slow down the process and lull us into a false sense of security. Andy.