Originally Posted by
DaveSSS
A short-lived headset makes me think that either your luck is bad and you got a defective one, you ride in the wet a lot or you don't adjust it properly. If the first headset lasted 20K, so should the second.
You can't adapt the frame to another headset design. The CK headset requires a much larger 44mm bore.
A common mistake is apply insufficient bearing preload. I apply enough force to make the fork drag a little as it's turned, then back up the bolt, by 1/4 turn or even less - just enough to allow the fork to self-center.
I've had FSA headsets on several bikes. One has been in use since 2004 and it still works fine.
I have no integrated headset frames but I have had excellent results with FSA cartridge bearing press-in headsets and, I assume, they use the same bearings. I have over 17,000 miles on an FSA Orbit X and it is still in excellent condition.
I also agree on the preload requirement. I've read recommended preloads of from 8 to 20 inch-pounds for various model cartridge bearing headset.
Finally, the 2004 Merlin frame the OP describes may be one of the first integrated headset frames ABG designed Litespeeds of the same year had the same problem. These frames were designed to accept both Cane Creek and Campy standard headsets and, apparently didn't work properly with either. Litespeed would modify the frames under warranty to take only the CC standard if the owner complained.