shoota 

What could have caused this? And how screwed am I?

Bianchigirll 

Can we get a good profile pic? I’m betting that was an accident. A frame builder could likely replace it but the cost may be prohibitive, and decent chrome replacement might be a more economical and faster solution

how does the area around the DT lug look?

shoota 

Like this? Sure looks straight to the naked eye.

juvela

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likely due to a frontal impact

there is internal butting in that portion of the tube so it is fairly robust

you could easily check the steerer with a straightedge to examine it for deformation

if deformation present can be aligned with the aid of a mandrel from the inside of the lower end

bulge can be reduced with rolling blocks

does not appear a failure risk


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TPL

Accident damage ....is the bicycle still rideable ? ....if the bicycle can be ridden with no ill effect handling-wise, just ride it....do NOT attempt to 'straighten' this fork

shoota 

Thanks guys. It doesn’t appear to affect anything, the fork looks straight so I’ll likely just ride it. This dang bike I tell you what...

Sluggo

Is this a recent acquisition and you don't know the history?

Since it appears to be aligned but slightly damaged, I would speculate that it was bent in a crash and subsequently straightened. If it is straight enough for the headset to work without binding, I would say you were good to go.

Is there any sign of damage on the head and/or down tubes behind the lugs?

Juan Foote

It appears to me that not only can you see bulge at the front, but also the stress marks to the side as well as changed position to the rear. I like my teeth so am very sensitive about riding bikes with possible fork damage. YMMV. Got good dental?

/wouldnotride

TugaDude

I'm with Juan Foote on this one. Most of us go by experience and maybe it would be OK, but if not it literally could cost you your life. Is that a gamble you wish to take?

merziac

Maybe you just need an old wooden plug from a Pug?

Mad Honk 

Shoota,
You should likely give me a call. I have a chrome aftermarket fork here that should work for you. It is Tange chrome moly and fits 700c. Price is very reasonable. Smiles, MH

Doug Fattic 

Framebuilder here. My 1st thought was that the bulge might be extra brazing material (brass or silver but probably brass). It is pretty common to see some right above the crown. A steerer is butted and very thick at that end. I have a hard time believing any kind of accident would bend it there. Sand away the paint and see if that really is a bulge is something else besides the actual steerer.

randyjawa 

The idea of brass or silver solder is very good. To me, there is one other possibility - press pressure. If the head set was too vigorously pressed into the head tube, that might account for that kind of bulge. To that, I have to agree with at least one of my fellow members. Fork failure can prove catastrophic to both the bike and, more importantly, the rider.

shoota 

Done.

dddd

A few swipes with a coarse file on that lump will produce filings, which can then be tested with a magnet.

They will be either brass or steel, but that crown is brazed on so I'm all of 95% certain that the "bulge" is brass.

Drillium Dude 

Can you feel a crease when you put your finger up into the steerer tube from the fork crown? If not, I agree: excess brass from the build process.

Nice looking frame.

DD

shoota 

Nope, I’ve looked up into the steerer tube very closely and it’s completely smooth. I think it’s safe to say it’s just excess brass. Which is perfectly in line with the quality of this frame’s build overall :/

Drillium Dude 

Cool - that is good news; it'll build up into a fine bike, then

DD

shoota 

I’m looking forward to it. Initial impressions are that the angles are steep, the only ride I’ve done on it (around the block) seems to indicate very quick steering.

Doug Fattic 

That's brass (well, frame builders call it brass but it is really bronze). That was the only option that made sense to me. Extra brass is common in that area because it is challenging to get just the exact amount in when brazing. Steerers are so thick at the bottom it made no sense it could have somehow bent or bulged. Now it is common that up close to or on the threads - where the steerer is much thinner - a steerer can bulge when a quill stem is over tightened.

shoota 

Thank you for chiming in and setting the record straight. At first glance it was strange the paint had come off there. But it also seemed strange that accident damage would bulge a steerer on the FRONT side. Sanding it down was a good call and I wouldn’t have immediately thought to do that. Thank you.

shoota 

Thanks MH, I think we’re good here. Also, you should be getting something in the mail very soon, if you haven’t already.

Drillium Dude 

You know, the more I look at this the more I think you should mine that vein and take the material to your nearest Assay Office; you might find that the frame pays for itself!

DD

Chombi1 

That's not weird, compared to what I experienced with a brand new 1984 Peugeot PSV I purchased when I was in college.
After riding it for a couple of weeks, a similar looking bulge developed right above the lower lug of the head tube.
Along with the bulge was the constant loosening of the Stronglight A9 headset on the bike. The head tube was actually accordioning on me and the bulge was getting bigger as I rode the bike.
Brought it over to the Peugeot dealer I bought it from and it got them scratching their heads on what was causing it.
They eventually agreed to exchange the bike for a different one from their stock as a warranty replacement.
cement.The shop owner sent the bike back to the main distributor for them to try and figure out what happened.
I suspect it had something to do with the heat treatment of the head tube done wrong and caused the tube to be too ductile.

xiaoman1 

shoota,
Late to the party, but from the first photo it appeared to me that it was excess weld/brazing and the loss of paint was due to installation and scrapping of paint...glad it all worked out. Good call from dddd to further explore
Best, Ben