What is wrong with my Shimano 105 5800 front derailleur? Background:

I've installed a complete new 105 group (this bike is a brand new custom build) on a Civia Hyland frame.

The rear wheel has a white industries CLD disc hub for the 11 speed cassettes.

The Civia doesn't have a brazed on cable stop, so I've installed a clamp on cable stop on the down tube for the FD cable.

I have an inline barrel adjuster at the cable stop. The Civia has adjustable dropouts, so I've put them as far back as possible, resulting in an effective chainstay length of around 435mm or so. The wheel is in the correct orientation, I've checked side to side length (wheel edge to downtube) and it lines up with the downtube.

I've installed the FD according to the shimano FD shop manual for this dérailleur.

The FD is a clamp on version.

I have plenty of tension, the FD (5800) shifts great and fast, the problem is rubbing.

I can actually adjust the FD so that BOTH the small front/large rear and large front/small rear rub on the FD. I can adjust it so that it rubs at both extremes! Note that I don't mean the cross-chained extremes here, i.e., big/big and small/small, these are ok with the trim positions (I also don't care about these, since I don't use them)

When in the small/big combo it rubs on the inner part of the FD cage. When in the big/small combo it rubs on the outer part of the FD cage.

I'm sure it isn't in a trim position. I'm using a 5800 shifter. I've tried both cable adjuster positions at the pinch bolt. There is slight runout on the big chain ring, but it is pretty small.

In the small/big (front/rear) combo, the chain rubs on the inner part of the cage. In the big/small combo, the chain rubs on the outer part of the cage. It is like my shifter isn't pulling enough cable on the final trim to big shift, or that the chainrings are actually spaced too far apart (I suppose I should pull the crank off and check the latter).

This also occurs with both adjustment screws backed all the way out, to ensure that the full shifter cable range is being utilized.

The chainline is correct at 43.5mm.

Has anyone else seen this problem? Do you think I have a bad shifter?
I've been riding the bike and really took a look today at the shifting while riding.

In the big/small combo, it looked like it just wasn't pulling enough cable to get it over far enough.

While I was riding I had an idea, perhaps the cable position coming from the cable stop had an effect (it should since it is basically a projection of the pull onto the the FD lever arm).

The cable stop was a clamp on aftermarket one, since the Civia Hyland doesn't have cable stops.

When I got home I decided to test it some more. I did two things :


moved the cable stop up and down
rotated the cable stop around the down tube


I managed to find a position where it worked! Barely, the tolerances on this thing are tight, but I can get it positioned where it barely doesn't rub now on small/big and on big/small.


The cable stop was too close to the FD, it needed to be moved down.
The cable stop was rotated too far away from the FD, it needed to be rotated closer to the centerline of the downtube.


This fixed the problem, these new FDs have very tight specs, it still barely, barely doesn't rub.

At least I have a cable stop that I can move around, if the cable stop were in a fixed position I couldn't have fixed this.