Originally Posted by
Infidel79
I say try it out...it's not really a safety issue, as it is only used to set the preload on the headset. Once that is set, the stem holds everything together. With the stem properly installed, the star/expander nut can theoretically be removed.
+1 The star nut/expander plug does absolutely nothing once the stem is tightened down. Its sole purpose is to preload the headset. If the expander plug stays in place enough to set the preload go ahead and use it. Otherwise you may have to use the star nut and or find some way to get the plug to "stick" better.
By the way, a star nut setter isn't necessary, if that's what's worrying you. Just thread in the screw (or an old screw you don't care about) then tap the star nut in with a hammer. Get it to go in straight, if you can.