OK...I just got a PL bigfoot fork and wheels for WBB so I don't have to stand around waiting for the tide or if wind is going in wrong direction..with that said...I need a little help.

On top of the bolt (1st time ever) seizing up on me...here is the issue.

I put the two spacers that go in the bearings that are in the headset. Engaged the fork to run the bolt through and when I did it seems like an awful lot of play in there. (see picture). When I was doing this I noticed for the 1st time the welding from Factory was not so hot. Wind has been cranking up here for 3 days and I just want to try this thing before I go.

1. What size bolt runs through the headset to attach fork as I had to cut the seized one out and need to replace?
2. Being that the forks are made in ? Should I fill in the 3/16 gap between the spacers and fork so that it takes out the play or is this bit of wiggle room standard?

Turn the fork around. You have it mounted backwards.

Joking or for real...It seems to be the same looking at it from both ends but....It still doesn't account for the left side of the fork (on top) to be a 1/16 higher on one side....Do you see that?

I do see the foot pegs are on some type of angle so...This still doesn't account for the 3/16 of slop in the headset. That's what is worrying me. If I was to bolt this together and then grab the downtube I can move it up and down between space in fork a good 1/8.

Quote:

Originally posted by BEC Joking or for real...It seems to be the same looking at it from both ends but....It still doesn't account for the left side of the fork (on top) to be a 1/16 higher on one side....Do you see that?

No you should not have any wiggle when headset is properly tighted . Fork should spin in headset with no other movement.

Solution? Hopefully someone knows.

Do you have spacers on top and bottom...?

If memory serves, there should be a pair of top hats (reducers) in there. One on the bottom and one on top....and/or a tall spacer/tube thingy.

I might have it wrong.

Yeah, pretty sure there's supposed to be spacers as said above. Talk to awindofchange, he'll probably have what you need.

I have the headset...The bearings and two top hats....When I put them in the headset and run the bolt through there is at least an 1/8 of room between the two top hats and the fork. It won't matter how much I tighten bolt as it will only get so tight..

Very frustrating and quality as discussed on PL products in the forum is yet to be desired.
I'm pretty mechanically inclined so....I put two SS washers in-between the top hats (on upper) to make up for the slop...This seems to have done the trick but should not be necessary.

From the description and photo I see the top hat (spacers) in there - also called mushrooms and a few other things ... especially if you lose one.
Anyway when you slide a downtube in the fork it should "just" fit and on some buggies it's a tight fit and on others a very small amount of room (less than 1mm). If you put a wheel on a fork and tighten the axle bolt first then in most cases you will not be able to slide a downtube into the gap because tightening the axle bolt flexes the flange and there isn't quite as much space. So when assembling a buggy and people say my downtube doesn't fit in I ask if they have the wheel on and tight and loosing the bolt will give the room - so it is a clean tight fit.
Yours looks like it's wonky on an angle from side to side and too much space above that spacer.
I wonder if there is a slight different between the headstock on the flexi vs PL - I think they should be the same. Regardless the top of the fork should be level not slanted.

I have a PL kinked downtube and fork...brand new....I agree with there not being any slop and top hats just fitting in there. That was my issue...There is a good 1/8 gap between top hat and fork.

I also measured some things on the fork and welding from factory is almost off a 1/8 which is why the top is out of whack. When I put the two SS washers in there the fork became tight in the fork as it should be.

OK another pic...top hat is in and you can see the amount of space still in there. I filled that in with x2 washers but I shouldn't have to.

Quote:

Originally posted by BEC I have a PL kinked downtube and fork...brand new....I agree with there not being any slop and top hats just fitting in there. That was my issue...There is a good 1/8 gap between top hat and fork. I also measured some things on the fork and welding from factory is almost off a 1/8 which is why the top is out of whack. When I put the two SS washers in there the fork became tight in the fork as it should be.

Looks like you're missing the nylon bushes ??

All the (steel) bushings are present and properly in place. As Mark says, it is normal for the downtube's headstock to be a snug fit with slight compression to the top-hat spacers. Besides the excessive clearance, the asymmetry of the bends and the crookedness of the bolt's vertical axis is obvious. This fork is defective and will be replaced immediately and the PL people are going to hear about this in the morning.

While I have seen a few bad headstocks right off the shelf (bad batch of welds mentioned in another thread), I have seen this only once before that I can remember, where the top of the fork was not formed properly. PL has always made good on the very few problems I have had.

As a business man and someone actively involved in this sport, I can not say enough about Angus and his business Coastal Wind Sports. This is one of many reasons to do business with distributors on the forum. They are here to help you when things don't go exactly as planned..Try that with someone who you purchased items from over the internet...

He has taken care of everything and I still feel good about the entire transaction.

THANKS ANGUS

BTY The headstock on downtubee measures 3 inches...(not including the top hats flange)
space between cross bars on the fork is app. 3 5/8

Glad you are getting it worked out! Nothing worse than not being ready when the time comes! That reminds me, I have a lot of work to do before WBB!

See you on the beach soon!

This is a crappy story wit ha great ending. Glad to this work out well in the end. Another reason to be here.