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sbbohr
Have done all of the above apart from torqued... so could be the reason.
It's my only carbon steerer so very possible user error if I'm needing to treat it differently to aluminium.
Have just faffed and retightened, adding extra spacer for good measure over steerer. Will see how it goes, when I'm eventually commuting again. Reminded me that the expanding nut assembly looks wrong every time I see it...but I don't know any better. Certainly looks like top surface should be flush with top of steerer right?