Carbon fork steerer too narrow for bung…

Trying unsuccessfully to get a bung into the carbon steerer of a new set of forks. A variety of 1 and 1/8 bungs don’t want to play – even one I’ve filed down a bit. A one-inch bung doesn’t engage, even at full expansion.

Is it normal for these to be a very tight fit even when not expanded? So far I’ve tried to tap them in gently with a rubber mallet, but it doesn’t look to me like they’re designed to be whacked in hard.

I take it a star nut is out of the question on carbon?

Bit annoying as I was trying to finish a build for my daughter today, and it’s starting to look like the forks may have to go back.

On one fork?

😀

How on Earth did you guess?

Post Office on Monday morning then?

Just kept filing the ‘cones’ and even the sleeve till I got it to fit, took ages. I believe the FSA bung is supposed to work OK, I guess it’s slightly smaller than most.

Yeh, looked like even the sleeve would be a bit of a squeeze. Did you end up hammering it in?

Oh and don’t look at the alignment of the calliper mount either, country mile out! I do keep buying on one stuff because it’s great value but it seems hand finishing is required more often than not!

Didn’t hammer it in as such but a mallet was used, more than hand tight but not damage it hammer tight. Would be able to remove it if necessary, that gives you an idea.

I had to buy a 1 inch bung for my on one carbon forks as the 1 1/8 one was too big

Oh and don’t look at the alignment of the calliper mount either,

Not sure I can be arsed if I have to bodge that as well. May just go and get an Exotic Carbon one instead. Same price.

Didn’t hammer it in as such but a mallet was used, more than hand tight but not damage it hammer tight. Would be able to remove it if necessary, that gives you an idea.

I’m still a long way off that. Not sure that will ever be possible. Anyone know of any one-inch expanders with enough range to engage?

Just fitted a new disc, looks as though the old disc was more at fault (out of square) than the calliper mount, well that and me forgetting that qr forks sprag apart without the qr! There’s a relief for you. If its the monococque then persevere with it, it is a very good fork, far stiffer yet more compliant than the exotic ‘carbon tube’ fork I had.

I had exactly the same problem,i had to machine a bit off the top and bottom bits and file the slotted centre section slot so that it closed up a bit more,lucky I can do stuff like this at work.They are great forks though,so worth the effort.

Cheers, could take a while with a hand file though.

Anyone know of any bung which is much narrower? Is the FSA one really skinny?

Success! Not to bad once I thought about the alternative – dealing with on- one customer services.