It feels fine when not done up but doesn’t turn at all when qr is tightened. Not had hub apart so it’s not a spacer issue. I’m assuming it’s a bearing in the freehub but before I buy another (it’s a prime freehub, don’t think the bearing is replaceable) can someone confirm this is the likely cause
if it used to turn but now doesn't, then clearly a bearing(s) has seized. Strip and replace the bearing(s).
If it was a Hope hub I'd say you'd omitted the spacer washer when rebuilding it . . .
Any other changes? We had a freehub do this and it was because tolerances were already tight and the rivets on the back of the cassette must have been a nanomillimetre away from some part of the hub body or spoke head or something. Tightening the QR was enough to close the gap and the cassette would stop spinning.
We just needed to change or rotate the spacer between cassette and shoulder if the freehub
My bitec hub did a similar thing because I'd got the seal the wrong way round. Could that of happened?