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Thanks all for the help. I'm not getting anywhere with Condor. I left the bike with them today and they've concluded that everything should compress nicely when I built the bike up properly and compress the topcap etc. I bought it as a frame and fork so haven't got to the full build stage yet. They use the same size headset bearing on all integrated frames.
Again, i'm incredibly dubious. Every bike on the showroom floor has a significantly smaller gap between fork and headtube, even the customer sales team acknowledge there's a bigger gap on my frame than the others.
I've concluded that if there's nothing else they can do, I'll try and build it up and see if that works - on the proviso that if that doesn't fix the problem they'll find another solution, despite me having to cut the steerer etc.
miloas-
they've concluded that everything should compress nicely when I built the bike up properly and compress the topcap
I think I'd reject the frame and fork. If the components are mechanically correct, I'd accept that kind of aesthetic flaw on a $200 chinesium beater, but not on a supposedly premium brand.
I'm still worried that the fork is a QC reject candidate or somebody has fucked up and installed the wrong bearing, but if Condor want to stand behind their claim that it's fine, tell them to install the headset and preload it to the correct setting and see how much gap you're prepared to accept as a visual flaw with their guarantee that it's mechanically sound.
gbj_tester
If that's where the error lies, then yes. It needs checking with a goniometer. That might not be the issue, it could be that the fork crown is way out of tolerance. Having once been viciously attacked by whichever monkey tried to make it fit, it certainly needs close inspection for any damage.