Re:
Hi Keith.
I was hoping you would come along with your trade experience , knowledge .
The races are correctly seated in the cast lugs and I have fitted the correct size balls as far as i know .ie the same size as the ones that came out .
I may just have to strip it down and reassemble it, checking everything again as I go.
I have rebuilt this type of head set before without problems .I had one on a Saxon twin tube which the different size ball bearing arrangement top and bottom and races that seated into cast lug.
The only thing I can think of that may be causing problems is that I am using a stem that has an expander bolt fitted. As far as I know the correct period stem would not of had one .
Plenty of time available at the moment to sort it out.
Paul .