Hygge Aero Carbon Frame

[lkbfreak]

So my LBS built a bike with my Hygge frame that I'd received earlier this month. They said it went very smoothly. However, now that I've gotten it home, I noticed what seems like a lot of space between the final headset spacer and the frame. Talked to Hygge about it and they they think "it is not flat when screw the bolt", though I'm not sure what that means. Anyone have some thoughts on why this extra space?

Yep, that's too much space between headset cover and the frame. It should be a 1 mm gap between them , just enough so the cap is not rubbing the frame. This looks like your compression ring is maybe upside down or something but isn't certainly right! Get back to your LBS and explain that it should be as described - they should know better!

Take a look at the post #635 - this is how it should be done right. A member un the post #653 also has similar problem like yours so I'm wondering if there's something wrong with the c-ring or the whole headset... Spacers have pins that fit into the lower spacer so they stack up and line nicely - headset cover too has a two pins that should align with the compression ring and maybe they are not fitted correctly into holes thus making the cover sits high and tilted. I would disassemble it and try to assemble it again.



You see how the c-ring has a hole just slightly to the right of the blue marker? - it should align with the pin underneath the headset cover.

FOR NOW I WOULD NOT RECOMMEND YOU TO RIDE THIS BIKE UNTIL FIXED!!!

Cheers

[TidyDinosaur]

Yep, that's too much space between headset cover and the frame. It should be a 1 mm gap between them , just enough so the cap is not rubbing the frame. This looks like your compression ring is maybe upside down or something but isn't certainly right! Get back to your LBS and explain that it should be as described - they should know better!

Take a look at the post #635 - this is how it should be done right. A member un the post #653 also has similar problem like yours so I'm wondering if there's something wrong with the c-ring or the whole headset... Spacers have pins that fit into the lower spacer so they stack up and line nicely - headset cover too has a two pins that should align with the compression ring and maybe they are not fitted correctly into holes thus making the cover sits high and tilted. I would disassemble it and try to assemble it again.

FOR NOW I WOULD NOT RECOMMEND YOU TO RIDE THIS BIKE UNTIL FIXED!!!

Cheers

Yeah, it's the tilt that's more worrying than the gap...

[velostar]

You see how the c-ring has a hole just slightly to the right of the blue marker? - it should align with the pin underneath the headset cover.

Cheers

So thank you for this diagram and feedback. I removed the handlebars and spacers so I could see exactly how the bearings, c-ring (i.e., split ring in the diagram), and headset cover (i.e., group cover in the diagram) were fitting. I also compared with Henry Chung's frame build videos to ensure everything had been placed correctly. I also ensured that the headset cover's pin was aligning with the hole in the c-ring.

After spending some time on this, I've concluded that there's something wrong with the interface between the headset cover and the c-ring. The headset cover simply won't descend enough to completely cover the c-ring and remove the gap. Here's an image of how the c-ring is fitting into the top bearing. This seems all correct:



Now when I place the headset cover over the c-ring, this is as far as it goes:



Again, I ensured that the headset pin was aligning with the hole in the c-ring.

I compared my c-ring with Henry's c-ring in the video of the new EPS frame he did a couple months back. The look to be the same, but perhaps different color?

Am I missing anything here?

[TidyDinosaur]

Assemble everything and tighten everything. The gap will get smaller

[lkbfreak]

So thank you for this diagram and feedback. I removed the handlebars and spacers so I could see exactly how the bearings, c-ring (i.e., split ring in the diagram), and headset cover (i.e., group cover in the diagram) were fitting. I also compared with Henry Chung's frame build videos to ensure everything had been placed correctly. I also ensured that the headset cover's pin was aligning with the hole in the c-ring.

After spending some time on this, I've concluded that there's something wrong with the interface between the headset cover and the c-ring. The headset cover simply won't descend enough to completely cover the c-ring and remove the gap. Here's an image of how the c-ring is fitting into the top bearing. This seems all correct:



Now when I place the headset cover over the c-ring, this is as far as it goes:



Again, I ensured that the headset pin was aligning with the hole in the c-ring.

I compared my c-ring with Henry's c-ring in the video of the new EPS frame he did a couple months back. The look to be the same, but perhaps different color?

Am I missing anything here?

Good. Now put all the spacers on and then the handlebar and compress it as much as possible and tighten first the cover bolt so it compresses everything down (I used 4 Nm). When everything is compressed then torque side bolts of the stem to 5 Nm. That should do. Or maybe the c ring is too thick because mine came in silver, not a black one.

Did you put the bearing ring at the bottom of the fork steerer first cause it makes 2 mm difference.

At least the headset cover is not tilted so it's a good sign. You're on a right way to solve it.
Hope i helped. Good luck!

[velostar]

Good. Now put all the spacers on and then the handlebar and compress it as much as possible and tighten first the cover bolt so it compresses everything down (I used 4 Nm). When everything is compressed then torque side bolts of the stem to 5 Nm. That should do. Or maybe the c ring is too thick because mine came in silver, not a black one.

Did you put the bearing ring at the bottom of the fork steerer first cause it makes 2 mm difference.

At least the headset cover is not tilted so it's a good sign. You're on a right way to solve it.
Hope i helped. Good luck!

It's hard to imagine the headset cover going any lower. Seriously, I've tried to get it lower! Plus, Henry's videos show the headset cover nearly flush with the frame before the handlebar cover is placed and tightened down to compress the assembly. Possibly it could happen but here I run into a possible LBS mistake. It seems they cut the steerer tube so that it is exactly flush with the top of the handlebars, whilst most everything I've seen shows the top of the steerer tube about 3mm below. This is with the maximum number of spacers so I can't add any in order to raise the bars. Did they mess up?



Confirmed the bearer ring is at the bottom of the fork steerer.

Hygge showed me a short video of the c-ring/headset cover interface that shows the c-ring in black like mine. However, their headset cover appears to be slightly different. I've reached out again today and will probably get an answer tonight.

Thanks for your help!

[TidyDinosaur]

They did not cut enough no. You can use a standard round spacer on top of the handlebar with a round top cap to test it though (if you have them lying around)

[lkbfreak]

It's hard to imagine the headset cover going any lower. Seriously, I've tried to get it lower! Plus, Henry's videos show the headset cover nearly flush with the frame before the handlebar cover is placed and tightened down to compress the assembly. Possibly it could happen but here I run into a possible LBS mistake. It seems they cut the steerer tube so that it is exactly flush with the top of the handlebars, whilst most everything I've seen shows the top of the steerer tube about 3mm below. This is with the maximum number of spacers so I can't add any in order to raise the bars. Did they mess up?



Confirmed the bearer ring is at the bottom of the fork steerer.

Hygge showed me a short video of the c-ring/headset cover interface that shows the c-ring in black like mine. However, their headset cover appears to be slightly different. I've reached out again today and will probably get an answer tonight.

Thanks for your help!

Just like @TidyDinosaur wrote, your LBS didn't cut the steerer correctly! Your LBS is BS because they should have warned you about something's wrong and advise you on possible problem/solution and not let you leave the store with your head in the sack! They are either incompetent or utterly lazy!

As already advised, you can put regular round headset spacer and top cap and try if everything compresses.

The only other thing I would suspect is that compression ring measures too thick. Hygge changes small parts like underwear, probably depending on where they can source them. They are not certainly producing them. We've seen different spacers, compression plugs, seat clamps, handlebars etc. so it would not surprise me if they changed something. Although in the end all those parts should be compatible on different bikes...

Personally, I would return the bike to your LBS and ask them to do the job properly. You paid for it probably so it's their job.

Just take your time, everything will be solved in the end, just don't force anything so you don't damage the frame. Soon you'll be enjoying riding the bike and be perfectly satisfied.

[dcalcada]

Hi guys.

I've received my frame and quality control seems not the best...
Would you accept this?







Got me worried..

[lkbfreak]

Hi guys.

I've received my frame and quality control seems not the best...
Would you accept this?







Got me worried..

Yep, looks like a big one - contact Hygge and ask for replacement.

[dcalcada]

Already contact them.. they say it's safe and if anything happens there's 2 years warranty... Wtf is this?!

https://youtube.com/shorts/p_-xBr9Zvko?si=iO_lBYCkMT8sn2Ac

[lkbfreak]

Already contact them.. they say it's safe and if anything happens there's 2 years warranty... Wtf is this?!

https://youtube.com/shorts/p_-xBr9Zvko?si=iO_lBYCkMT8sn2Ac

If anything happens you'll end up in a hospital!  Then the warranty is worth nothing. If they claim that it's safe to use it, I would suggest you to take the frame to your local bike shop and ask a mechanic to evaluate it. Even better if you have a carbon expert somewhere in your area. This is kind of delamination or bubbling and may or may not have impact on the frame. Seems it's right where the top tube merges with steerer tube and looks like some kind of resin bubbling or similar or like someone broke it. Maybe this happened while removing EPS liner...

[TidyDinosaur]

I think people are really starting to over-analyse these frames... It's the inside, it does not have to be perfect. Just check if the carbon is not too thin in that place (tap it, push it... )
It's a 500EUR frame for god's sake...

[BeR]

I think people are really starting to over-analyse these frames... It's the inside, it does not have to be perfect. Just check if the carbon is not too thin in that place (tap it, push it... )
It's a 500EUR frame for god's sake...

Life is worth more than 500 EUR. (I don't say that the frame is not safe because I don't have the knowledge).

[Nkearb]

If anything happens you'll end up in a hospital!  Then the warranty is worth nothing. If they claim that it's safe to use it, I would suggest you to take the frame to your local bike shop and ask a mechanic to evaluate it. Even better if you have a carbon expert somewhere in your area. This is kind of delamination or bubbling and may or may not have impact on the frame. Seems it's right where the top tube merges with steerer tube and looks like some kind of resin bubbling or similar or like someone broke it. Maybe this happened while removing EPS liner...

I dont know where you are finding a LBS that can identify carbon defects. I bet I could walk into any one of my LBS and no one in the place would have ever heard the word delamination. I went to the LBS closest to me once and asked if they had brake pads fit for a regular shimano road caliper and they took me to their mechanics, and I asked again and they all looked at me with pure confusion.