Airwolf YFR068 - 2023 Gravel Frame

[frankpaul1]

I'm not sure if this helps, but what I did was tighten the expander plug whilst it's in the fork, then assemble the top plate and attach the top hex screw not too tightly. Now, the expander plug is firmly in the fork and there's no play.

It seems to keep slipping up after a few rough rides even with carbon paste. Not a concerning amont of play, but I'd like the plug to stay in place . What are my options? Is there a longer plug available? Is there some paste I could use. Any other tips?

Could the issue be that the edge of the expander plug is just too small to grip the fork and it just keeps slipping?

[blublob]

Is the stem slipping up or just the expander with the cap? There should be a negligible amount of force pulling the plug out of the steerer, as after tightening the stem the only use of the plug is to hold the cap.

The highlighted parts shouldn't be expanding and/or gripping anything. The ledge is just there so the plug does not drop into the steerer by accident.
The expanding parts of the expander plug are the parts with the crosshatched groves further down the plug.

[frankpaul1]

I can't imagine the stem slipping up. It's tightened to 6 Nm. It looks like the expander is coming up by about 0,5mm but it's enough to cause a bit of headset play. Hope to hear done other builders experiences with this frame and how they solved it.

[Phaxe]

It seems to keep slipping up after a few rough rides even with carbon paste. Not a concerning amont of play, but I'd like the plug to stay in place . What are my options? Is there a longer plug available? Is there some paste I could use. Any other tips?

Could the issue be that the edge of the expander plug is just too small to grip the fork and it just keeps slipping?

That doesn’t look right at all. Mine sits completely flush with the top of the fork.

[Phaxe]

I can't imagine the stem slipping up. It's tightened to 6 Nm. It looks like the expander is coming up by about 0,5mm but it's enough to cause a bit of headset play. Hope to hear done other builders experiences with this frame and how they solved it.

I'm trying to think of the things that could be causing this. Did you use the SL7 bearings? Or the bearings that came with the bike? Also, did you sand down the paint on the fork so that the bottom bearing is sitting properly flush? I didn't use any carbon grease for the expander plug, but I did have to sand down the edges of it to sit flush within the stem, like This Is Dog suggested.

How are the gaps when you tighten everything up? Below is a picture of mine for reference.

[frankpaul1]

That doesn’t look right at all. Mine sits completely flush with the top of the fork.

Haha, it does of course start out completely flush. But ends up a bit above the fork for some reason. This image is exaggerated.

[frankpaul1]

I'm trying to think of the things that could be causing this. Did you use the SL7 bearings? Or the bearings that came with the bike? Also, did you sand down the paint on the fork so that the bottom bearing is sitting properly flush? I didn't use any carbon grease for the expander plug, but I did have to sand down the edges of it to sit flush within the stem, like This Is Dog suggested.

How are the gaps when you tighten everything up? Below is a picture of mine for reference.

I've used the SL7 bearings and the SL7 compression ring. I've sanded the edged of the cap so it sits flush. I think I did al the right things. It compresses fine at first, just slips a tiny bit after a couple of harsh gravel roads.

[edinhog7]

I had a little play and the expander plug would go up. Now I'm using 10Nm of torque on the plug and it seems that so far, it has solved the problem.

[Phaxe]

I've used the SL7 bearings and the SL7 compression ring. I've sanded the edged of the cap so it sits flush. I think I did al the right things. It compresses fine at first, just slips a tiny bit after a couple of harsh gravel roads.

I had some creaking in the headset so I loosened everything up to grease up the bearing, but then for the life of me couldn’t get it back to a position that didn’t give me headset play.

I ended up combining two hobbies I never thought would combine - woodworking and bike, and clamped the bottom of the form and the stem, then tightened the stem, then the expander plug and it’s fixed it.

Perhaps give that a shot? Below is a picture.

[Phaxe]

Last Saturday I put the bike to test during one of Europe's biggest gravel events, The Traka in Girona, Spain. First time for me and joined the 200km route with 2500m elevation. Bike got some serious beating and did not let me down, it's still in one piece! 

https://www.thetraka.com/

I'm just wondering what you used as adhesive for the chain stay protector from cervelo? My bottle boss, chain stay and bottom of the frame protector is arriving this week.

[BeePiers]

Those parts come pre-sticky with adhesive.

[frankpaul1]

I had a little play and the expander plug would go up. Now I'm using 10Nm of torque on the plug and it seems that so far, it has solved the problem.

Okay, so an update. I torqued it to 10Nm and it looked great, no problems for two rides. But the last ride a little headset play returned and upon checking the torque on the expander bolt it was loosened quite a bit. Should I use loctite or similar on the expander bolt to avoid it from loosening from the vibrations?

[edinhog7]

It would be interesting to test.

[Phaxe]

Okay, so an update. I torqued it to 10Nm and it looked great, no problems for two rides. But the last ride a little headset play returned and upon checking the torque on the expander bolt it was loosened quite a bit. Should I use loctite or similar on the expander bolt to avoid it from loosening from the vibrations?

I don't think it would hurt.

I wonder whether these might help with the issue?

https://www.aliexpress.com/item/1005005898023414.html?pdp_npi=4%40dis%21AUD%21AU%20%2443.44%21AU%20%2443.44%21%21%21205.20%21205.20%21%40213db7b317244891585474963ef838%2112000034759216597%21sh%21AU%21117242412%21X&spm=a2g0o.store_pc_allItems_or_groupList.new_all_items_2007567614139.1005005898023414

[BeePiers]

I haven’t yet had this problem (probably at least until I send this message   
But what are the thoughts on the cervelo bonded fork insert?
I picked up a J&L insert just in case I needed it, but without modification it wouldn’t fit. Once I modified it by sanding down the outside of the unit to slide into the fork, the top wasn’t recessed enough to flush joint the top cap. I’m using the original one that came with my frame set.

I wonder if the bonded insert would fit and solve these slippage problems
https://www.excelsports.com/cervelo-fork-insert-kit-359?sku=568908&siteComingFrom=google.com_shopping&gad_source=4&gbraid=0AAAAAD_rVXA6TreRgK1hPwciTB03NpY_T&gclid=CjwKCAjwiaa2BhAiEiwAQBgyHi1fqSHR6YVSZYhUDE_lFUmTIXhUnu78HOtSiM-wgNj24AVBetaQqRoCCrIQAvD_BwE