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Cupcakes
@Skant
Just had a quick read through this thread, it seems like it's shaping up nicely. You've specced a lot of details I did on my Orlowski and tbh would on any other future builds. I think 1 1/8 external is definitely the way to go, seems pretty future-proof to me and is plenty stiff enough - especially when it's going on a steel frame which you ain't choosing for it's absolute stiffness characteristics.
Re headset: I went with a second hand Hope and can recommend. It was cheap and any spares needed in future can be bought direct. Also it came with a little rubber seal that sits on the outside of the crown race and is slightly angled so it makes the perfect transition from the (ever so slightly) larger diameter fork crown to the cup.
Did you/Rychtarski make a final decision on tubing?