Buddy2004 said:It's weird, because when fully tightened on the bars the clamp isn't fully closed - so a strip of tin can probably won't make any difference. The toothpaste solution I will try - spearmint or whitening?(!)
Can bars fail in this manner??? It's a pain to take everything off to investigate, as I would have to undo all the handlebar tape etc. It's difficult to see, but the only thing that would make sense is if the bars are in fact being crushed by the clamp, hence it not tightening effectively?
I will probably take the bars off to have a better look at it and then try the toothpaste, or consider new bars and / or stem.
Thanks guys
Rideastrong covered the mis-match possibilities very well. If your stem clamp is too small for your bars, you won't get proper clamp-up torque. It may look OK to the eye, but in reality the gap is too big because the clamp isn't sitting down onto the bars.
You could mess around with an inside micrometer, or maybe even use plasti-gage strips to check for gaps if you really wanted to investigate; I'd just replace.
Concerning failure possibility, yes. If the clamp is too small, it will be pinching the bar on the sides, which could create stresses which initiate a crack right where you can't see it. If you've "tightened the hell" out of the clamp bolts even one time, you could have a bolt fail on you, or the threads in the alloy stem let go. I'd spend some bucks and get rid of this problem now.