Originally Posted by
Rowan
Have you checked that the cups in the headtube are secure?
Apart from that, Retro has some good advice. Also, ensure that if you are using a brake cable hanger and/or a washer between the cone and the lock nut, that it is properly seated. Often, the hanger or washer with its keyed tab is difficult to get down the slot on the steerer tube. In addition, if you have any tension on the brake hanger (ie, assuming you have cantis, you haven't disengaged the cable from the brakes), the hanger will also be a bit difficult to seat. Technically, as you tighten down the locknut, the hanger and/or washer should flatten out and seat properly, but wear on the tab can prevent this from happening and you end up with a headset that isn't locked into place. At least, that has been some of my experience.
No, I didn't check the cups in the headtube... do you mean the part that is directly mounted onto the frame? Come to think of it, how do these stay in place? Are they just wedged in there? What is the best way to make sure they are seated correctly?
The headset doesn't have any brake cable hangers or washers... just two notched spacers with a tooth that fits into a gap in the threading. This is not the same as the "keyed washer" people are talking about is it? If not then I'm pretty sure this headset doesn't have a keyed washer.
As far as tightening the locknut sufficiently, I am getting it pretty tight... I've been securing the race while I tighten the locknut to prevent the locknut from turning the race as it tightens. I am using a big heavy adjustable wrench to tighten the locknut, I am fairly confident that it isn't loosening from undertightening, especially because it seems fine while I ride it until I hit a little bump, at which time I can feel something shift and I hear a weird hollow sound. This happens within 5 minutes of starting to ride it. To me doesn't seem like the locknut working its way loose but more like something which isn't properly seated shifting when it gets jostled... of course I am pretty inexperienced with headsets.
I am thinking to get some loose bearings give it another try, seems like a good saturday afternoon project. thanks everyone for help and advice.