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I can only find the CC 40 series in threadless?
Where are you looking? Wiggle have the Forty in an EC30 fitment
http://www.wiggle.co.uk/cane-creek-40-series-traditional-1-inch-headset/
Chris King do oversize cups, so if your head tube bore is over spec (30.0 is the normal spec, CK actually suggest 30.1 for their headsets) they can supply bigger ones, presumably in 0.2mm increments.
FWIW, I've had an M-Part headset which was a drop-in fit too, so it's worth taking a proper measurement. @Scilly.Suffolk could well be right, but there's no point paying for another headset until you know where the problem is. You'll need a suitable size telescopic gauge and a 25-50 micrometer. Obviously you're unlikely to have these about your person, but your local machinist should have them and will probably take measurements in exchange for a drink*
*see https://www.lfgss.com/conversations/226366/?offset=175#comment9384332 for exchange rate