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torqued everything
Including the preload screw? I think there's some benefit in giving that 5Nm after you've tightened the steerer clamp screws of the stem.
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Shims on top of the split ring at the top bearing. Make sure the outer lip of the bearing cover isn't contacting the frame before contacting the split ring.
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Next time it happens, check if any space has opened up between the head of the plug and the top of the steerer. That's still the most likely cause.
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I had this with my Kinesis 4SD during ultras. I moved to using longer, knurled expander bungs from aftermarket Italian supplier I think (Deda?) and I torqued everything properly (probably a little bit over because it was a metal steerer and fuck it), including the top bolt after the side bolts were done.
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gbj_tester
scultura
grams
hippy
@andylum
My gravel bike keeps developing some play in the headset after rides - I've tried everything I can think of but no success. Any ideas? So far I have tried different expander plugs (longer, more textured), ensured there's enough space above the stem to preload, torqued everything, tried different stems... at a bit of a loss now!