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Join Date: Feb 2012
Location: Rochester, NY
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Bikes: Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Mongoose Tomac ATB, GT Bravado ATB, JCP Folder, Stewart 650B ATB
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Hard to say the real cause but I'll take a stab and say it looks like poor brazing. The steerer bottom/crown looks to have no filler around some of it.
As far as the warranty goes I am surprised that the bike brand is saying that they will make the fork sub contractor deal with any claim. This type of failure is the worse case type. If a complete failure you loose all control and do a face plant. The bike brand really needs to step up and take care of the OP. It's the right thing to do a a manufacturer/brand.
I wonder if the CPSC would want to know about this? Andy.