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Galling - http://www.estainlesssteel.com/gallingofstainless.html
Essentially, the stainless EBB unit has nigh on fusion welded itself to the BB shell.
... wonder if it's an issue with the EBB??
Why one side only? Doubt it's galling as EBB went in slowly with loads of grease. But what do I know - I'm the idiot that got it stuck.
Tim - youre bang on, but how many would take the risk? Its really the guys who have been doing this for an age that know what they can & cant do/get away with. Ive been in it for 5 mins compared to most.
Threads look ok in the pics - but as already said, you cant really tell till you feel/run tool in.
Someone will do it for you - just call around locally to start.
Good luck fella.
I hope the moderators don't mind me participating directly in this discussion. I am the owner of Forward Components and the designer of the EBB.
Hundreds of EBBs have been sold by Forward Components and these two are the only known samples with issues of this sort. In fact they are the only known examples of our EBBs with any complaints at all. One of the posters here has been in contact with me. I have provided a great deal of advice and support, and he seems to have resolved the issue by having the bottom bracket threads chased. The original poster seems to be having a similar problem, and I suspect that there is a similar cause. The frame's bottom bracket shell and threads seem to be somehow malformed or contaminated. This could be caused by any number of manufacturing and maintenance factors, all of which can be investigated. The fact that both EBBs are having issues with opposite sides of the bottom bracket shell suggests frame issues and not EBB issues.
It is possible that there is a thread tolerance mismatch. That is, the EBB threads are at the high end of the permissable size range, and the frame threads are at the low end of the permissable size range. All EBBs are tested before shipping on a sample shell that is at the lower end of the size range, so there should never be a tolerance issue. That being said, it is possible that some manufacturers are using worn or undersized cutting tools, resulting in threads that are smaller than those found in typical frames.
My recommendation to the OP is the same as it was for the other customer who has posted here. Have the bottom bracket shell threads chased by a competant mechanic. If this does not resolve the problem then please feel free to contact Forward Components directly or through this forum.
Forward Components is not perfect, and it is possible that the problem arises from our end. If that is the case the parts will be repaired or replaced to the customer's satisfaction in accordance with our warranty.
Just to back up what Eric said - he's been fantastic helping me out (as hopefully came across in my earlier posts).
The good news is that On One got the EBB out using a vice but at the expense of the EBB driveside cup - but at least the frame's OK. As the non-driveside went in easily I'm working on the assumption that chasing the driveside should sort it out for another try with a new cup.
An update after a bit of a stressful time.
On One got the EBB out (involving a vice, drilling the installation tool and quite a few people turning the frame). They said the BB shell was fine and would take a standard BB, but I got the whole lot sent to Sideways Tim.
Meanwhile, Eric at Forward Components sent me a replacement driveside threaded cup and installation tool at cost - much appreciated along with the invaluable advice he gave throughout the process.
Tim chased the BB shell as the threads definitely needed it, and once that was done the driveside threaded cup went in by hand.
So, moral of the story is not to assume that a Ti frame will have had the threads chased - if that had happened at the outset there wouldn't have been a problem.
Big thanks to Tim for chasing a Ti frame when many others refuse, and to Eric for great support and advice.