Integrated headset presses into the headtube when top cap tightened.

Recently got a new FSA integrated headset, installed it all properly and stuff, but the cover above the top bearing gets pushed tight onto the headtube when I tighten the top cap. This results in handlebars that won't steer...

I have currently put a 2mm headset spacer (smallest I had) between the top cover and the bearings. It's mechanically fine now, but there is an unsightly and potentially dirt-encouraging gap just above the headtube.

I see my options as:

A) Replace the 2mm with a 1mm or 0.5mm headset spacer to reduce the gap.
(Does anyone know where I can get one of these?
The only one I've found is part of the Middleburn spacer set; which seems a bit of an expensive option for what I'm needing.)

Or B) I could remove the 2mm spacer entirely and try sanding/filing the bottom of the bearing cover thing.

Suggestions?

do you know the full name of the headset?
Sounds really strange. I have not come across this.
What's it like if you back off the top cap tightness 1/16 or 1/8th of a turn.

"This thread is useless without photos!"

There should be some thin (<1mm) metal shims that go under the top cap.

Maybe you need more of these if the tolerances on your headtube are off.

The headset is an "FSA IS Integrated" something. That's what comes on the otp bike and I remember looking that up and then buying the same to be sure that it would fit; irony.

@Scilly.Suffolk - pics and super-helpful diagrams incoming shortly.

Cane creek do these shims. A good shop will have them.

Here we have a crappy torch-lit phone pic of my bike, a lovely colour-coded diagram and a matchy matchy higher-res photo of the relevant headset parts.

The pink 2mm spacer in the second pic is the one that I've had to add in to stop the blue cover squashing down onto the headtube when I tighten the top cap.

And I haven't drawn it very well but the pink 2mm spacer sits real nice and snug and flush between the orange bearing contact ring and the blue bearing cover, so there's no worry about uneven wear, stress points, slipping or anything.

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Thanks, I'll ring round in the morning and see if any nearby shops have some.

Are the upper and lower bearings identical?

I had this with my Koga track bike, Hope (I think it was) do 0.4mm shims, one of which solved the problem.

I have never seen this before but i think Dammit is right. A tiny shim is 0.5 mm should aid in getting rid of the gap.

Thanks guys! I have now ordered two 0.4mm shims just in case one is not enough.

I would have done this at the start, but I was looking for "spacers" instead of "shims" and couldn't find anything below 2mm...

i think Dammit mechanical_vandal is right...

'sakes, I said this 7 posts and several hours before @Dammit yet he's getting all the glory?

I'm in a bad mood now.

Don't worry yourself, I spread my thanks equally.

Haha sorry chap I didn't see that. You are correct also.

@Samwell @BensBikeBits, thanks. I feel better now. :)