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Join Date: Feb 2012
Location: Rochester, NY
Posts: 18,094
Bikes: Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Mongoose Tomac ATB, GT Bravado ATB, JCP Folder, Stewart 650B ATB
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If only the clamp's ID were the issue one could shim just that and the clamp wouldn't be on the edge of closing up. However I agree with Francis in that the slot also looks to be closing up.
If a 31.8 post did fit and reduce/solve the clamp's closing up I would suggest living with that. But I don't remember the OP even trying this cheap fix. Seems that there could be more at stake in his eyes than a well riding bike.
There are reasons why a reamer cuts off size. Piece holding, cutting edge sharpness, lube among the biggies. I suspect the builder used a straight flute reamer, given the "The reamer apparently can't ream through a discontinuity (cut) in the sleeve" comment. If the reamer is an adjustable one chips stuck in the reamer blades' slots, or poorly seated blades, can also affect the cut diameter. A spiral reamer would reduce both concerns by a lot...
I do like the suggestion to have a third party expert get involved. But having been on all three sides of this possibility over the years I wouldn't hold my breath on the frame's builder accepting this assessment/arbitration. In the end the leverage a customer has, besides the bank/credit card claim possibility, is that of poor notoriety. I hope the builder cares about his reputation and steps up to work out a solution before that "nuclear option" is taken. Andy
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AndrewRStewart