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While working on my new bike I realized that a slightly shorter stem would be good, so I ordered an FSA OS-190 from Price Point. When the box of parts arrived it had been opened (photo), but as the thread locking compound on the screws was unmarred and there were no marks on the stem it appeared to be brand new. Unfortunately, after installing it I found a small crack in the stem cap, right near one of the bolts. Here is a photo of the stem on my new bike, with an arrow pointing to the cracked area.
Having torqued the stem bolts (cap and steerer) to FSA’s published 78 inch-pounds (FSA’s Stem and Post Torque Specs – PDF) I don’t believe this was caused by me during installation. This is also a particularly inopportune place to have a crack, as it could easily lead to stem/bar failure, which would likely result in a pretty bad crash. Even though it was relatively cheap and looks good on the bike when I request to return the item to Price Point I’m tempted to get a different stem, as I don’t want to risk there having been a bad batch.
Currently I’m thinking of a Thomson Elite X4, but now I have to decide on 0° or 10° rise. The aforementioned FSA is 6°, so 10° shouldn’t be too different…
UPDATE: Thinking about it, I wonder if follwing the FSA directions, which I followed, to “[l]ightly grease the bolt threads and under bolt heads” caused the problem. It’s my understanding that greased fasteners, particularly under the heads, are easy to inadvertently over torque, even with a wrench. This is because the fastener slips along much more than normal, and doesn’t provide the resistance that the torque wrench measures.