Jens (bendedheadtube) emailed me on 1st July:-
i bought a "Ragley blue pig 2011" frame 5 weeks ago which i ordered from "chainreactioncycles" along with the recommended Nuke Proof Headset 44IESS. (The frame serial number is RYW110488)
Unfortunately it seems, that the frame's headtube is slightly oval.
The diameter across direction of travel (left to right) is 43,4mm whilst the diameter alongside the frame (front to rear) is 44,1mm.
The bike mechanic which i commissioned with assembling the frame has doubts wheter the headset will fit into the frame without leaving any permanent damage and/or split the headtube. The mechanic also won't give any warranty if he splits the frame. He will refuse any claims, if any damage will occur during the assembling of the headset.
He will only install the headset on my own risk.
My Question is, wheter this is caused by a manufacturing mistake, and furthermore, if it is possible to send the frame back to you in exchange for a correct frame.
Now this isn't great. It does seem to have been a QC problem with the 44mm head tubes. Our factory have not been as rigorous as I'd have liked and our own goods in procedures hadn't picked it up either.
I told Jens, as he was in Germany, as the frame and the headset are a Hotlines product, and as we might as well have a go - to fit the headset. If it stuffed up, the worst thing we'd have would be a duff frame (which we had already) and a duff headset (that we manufacture). If it worked, he'd have a rideable frame. So I said:-
If, in attempting to fit a nukeproof headset to a ragley frame, any damage occurs, this WOULD be covered by your warranty.
Ask your mechanic to "go for it".
Jens' mechanic failed to get the headset in, so the frame went back to CRC to get sorted there.
Unfortunately there seems to have been an issue and the frame that Jens received back from CRC isn't right either - which is something I've had CRC looking into since Jens made me aware of it on the 26th.