DGoeder

So, through my own stupidity (or inexperience) I spent a couple weeks last summer riding my first new bike without one of the spacers on the steerer tube. I now know you're not supposed to do this. I've beaten myself up enough about it, so go easy on me. For reference, it's an aluminum frame with carbon fork.

After learning that was the reason my headset was making weird clicks when I turned, I put the spacer back in and everything seemed fine. At some point after that, I don't remember when it started, I began to notice a creaking type sound coming from somewhere. I spent most of this summer taking various things off and lubing or greasing just about every possible millimeter I could think of to get it to stop. Finally, I had taken every part I am comfortable working on off with no success. I threw in the towel and took it to the shop. First he thought I had an excessive amount of flex in the forks, so I spent $350 on a new fork. That was not the problem. I just got off the phone with them and am being told that he believes I damaged the head tube(?) where the headset lives.
I do remember reading when diagnosing the missing spacer issue that too loose of a fork can stretch that just enough, like he is saying, to cause the noise. It doesn't affect the functionality. It's just one of those constant noises that drive you crazy.

So my questions are:
1. Has anyone dealt with this before?
2. Do I need a new frame.
3. If I do need a new frame, does anyone have a suggestion on where to get a decent price. I'm not opposed to BikesDirect and such.

dvdslw

Sounds goofy to me? I don't believe even if it was just left loose that it would damage anything in the short time you rode the bike? Maybe, but I doubt it. I would suspect an out of spec or improperly preloaded headset. I find it a bit tricky to preload or tighten the headset bearings on a bike with a carbon fork because it has a plug that spreads as opposed to bike with an aluminum or steel steer tube that uses a star nut to help pull the stem down to preload the bearings. It's easier for me after doing it several times but still takes a bit more concentration to get it done. I wouldn't put much trust in the ability of your bike mechanic especially if he sold you a $350 fork for no reason? Any bike shop worth visiting would take the fork back off, admit they made an error, and come up with a fix. I would get a second opinion.

What model bike are you having trouble with?

DGoeder

His explanation was that I had cracked or separated the area where the carbon fork joins the steerer tube. When holding the front brake and pulling or pushing on the bars, there was a significant amount of movement from the frame. It may or may not have been caused be my missing spacer.

It's my Gravity:

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I really like it, and if a new frame is the solution, I'd like to try and find that one. But I don't think BikesDirect sells frames.

FIVE ONE SIX

so wait, you put the missing spacer in and then torqued down the stem cap and then tightened the stem bolts on the steerer, right?! then you grabbed both ends of your handlebars and, with your armpit on top of the saddle and your front brake pressed, you pushed forward and pulled back on the bars and you still have play in the headset?!

i would say to make sure the headset is in good shape, meaning the mechanic at the shop didn't damage anything and that everything is where it's supposed to be. you can easily drop the fork, so do so and look at the headset and where the fork and head tube meet to see for yourself. like someone already said, i wouldn't personally trust a mechanic that said i needed to spend $350 on a fork when they weren't either sure or right about it needing to be replaced. me personally, i would get least 2 more opinions from local shops and i would actually say something to the current mechanic about why he made you spend $350 on a new fork that you didn't really need...

DGoeder

I do agree that it seems a little odd. I try to do as much work myself, but this was outside my ability. This was my first time going to this guy, on the recommendation of a buddy.

It wasn't play in the headset, the fork area actually was flexing before he took it off. He did overhaul the headset before we started the fork discussions, so I think that is in good shape. The new one is already on, but I can't get over there to see anything until Monday. So, my eternal optimism is hoping that this was actually two issues where I thought it was just one. I'll definitely be sceptical when I talk to him. My money tree didn't produce a very big crop this summer, so I certainly dont want to buy something I dont need.

That said, because of what I learned with the missing spacer, I do think that the head tube issue is likely legit. My only thought on it I wonder if I have him pull the headset and grease the tube and then reinstal it, would that help with the creaking?

Thoughts?