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Steerer Tube Threading/Compression Bolt Size and Fork Failure

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red_spectre:
In the past I have read that forks that are threaded for 25x1.5mm compression bolts (correct me if I am wrong) are more likely to fail.

Sam from Tree, for instance, writes on their website (when describing their Okan forks): "I have found that forks with a 25mm compression bolt have a higher risk of snapping off the headtube."

Why is this the case? Is this based purely on anecdotal evidence? Can 1mm really have such a difference (24x1.5mm vs 25x1.5mm) and if this is the case why not use 10x1.25mm (like S&M/FIT) or 18x1.5mm (Cult) etc...?

When I browse forks online, it seems that the majority of brands are manufacturing forks for 25x1.5mm (a quick browse on Dan's for instance, will confirm this).
If they are inferior why is this still the case?

Stoked:
S&M uses a welded pc similar to a starnut and I think same goes for cult.  They don't thread their steerers

Whatever odyssey does (24?) is probably the best

weedbix:
It''s because 25 doesn't leave enough wall thickness

It's still used purely out of ignorance/apathy

Dr. Steve Brule:
1mm less wall thickness is a fair bit when it's on a steerer.

red_spectre:
But then, I wonder, if there is such a huge difference between 25 and 24mm compression caps and wall thickness, is a welded star nut (like S&M, Fit, Cult) not superior? Would, for instance, an Odyssey fork (which I run) not be better if it didn't have any threading? Or is there more to it?

Also, you would think that if 25x1.5mm forks were failing constantly, switching to 24mm would be an easy fix. Yet, I see companies like Shadow (who has had forks that evidently failed miserably) opting to develop oversized fork crowns (38mm) and what not... Could these brands really be that ignorant?

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