I've done a couple of searches and found conflicting answers about the effectiveness of expander nuts in an aluminum steerer tube.

However, my situation is a bit different since I already have both a star nut and expander nut available to me.

My Cane Creek Forty headset came with a traditional star nut and my Forte carbon fork (with aluminum steerer) came with an expander nut.

I'd rather use the expander nut since it would save me the 10 or so dollars it costs for a star nut setter, but I'm afraid that I may run into issues if it doesn't work.

Basically, what I'm asking is, is there any harm in me trying the expander nut first? Can it be easily removed and replaced with the star nut?

Thanks!

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.

I see.

My issue is, if the expander nut doesnt grip the steerer tube well enough to preload the headset, can it be easily removed altogether so I can use a star nut instead?

Given a choice. I'd go with whatever came with the fork. I don't know why but there is probably a reason that Forté included an expander nut rather than a star nut.

the expansion plug comes out easier than a star nut, that's for sure

+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.

If it doesn't hold well enough to tighten to the correct preload then it'll be slipping up the steer tube. In that case just use some bits to allow pulling it out all the way. Then use a star nut after.

The correct preload is very little anyway so it's unlikely that it won't hold well enough.

Hmm good points.

And I guess if the nut isnt even strong enough to stick, it must be pretty easy to remove.

Thanks for the advice guys, I'll be trying the expander nut first and I'll report back once its all installed.

Another way: A hex bit in a 3/8 drive adapter. Choose a "bit" that fits nicely into the star nut hole. It doesn't actually have to be a hex bit, it could Torx, Philips, or whatever. Then plug a 3/8 drive extension into the adapter. The extension gives you plenty of leverage to keep the star nut going in straight - and also transmits hammer blows nicely.

As long as the expander will grip the steerer interior adequately, it will work fine. I've used expanders in steel steerers as a temporary adjuater until I decided on the final trim height and they worked very well. I later replaced them with starnuts just as a cheaper alternative and to save an insignificant amount of weinght once I had the steerer cut to final length. It could have been used indefinitely.

As noted, you don't need an "official" starnut setter. A long bolt threaded into the starnut and driven with a hammer works fine. Once you get the nut started, remove the bolt, add the top cap and rethread the bolt. The top cap will act as a centering guide as you drive the nut to it's final depth.

I've used an FSA expander nut for decade with no complaints.

you have to destroy a star nut to get it out [done that],
or push it all the way thru the steerer tube and out the bottom

the actual force the headset adjustment bolt applies is not really needing to be much.

after all the adjustment is maintained by clamping the stem around the steerer.
not the top cap bolt.

plus you don't have concern about scratch induced stress risers
developing into cracks, in aluminum tubes.

Expansion is step1, then I'd grease the center bolt.

I had a tourist's bike sent ahead, to put together,
the previous mechanic put the expander together, in a carbon steerer fork, dry,
so taking the cap bolt out unscrewed the expander , then I had to get the rest of it out ,
then put it back together, the better way.

Turned a 5 minute job into a 20 minute one.

whoa thanks for that tip, i wouldve never thought to grease the bolt.