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Also, any idea how I've done this?
Is that the Scuzzy Logic with the plastic top cover? If so, it wasn't anything you did, it's just a natural consequence of using crappy plastic where there should be metal. The cover is squeezed between the spacer and the compression ring, and it tries to squish out. That puts hoop stress into the cover, and eventually it breaks.
gbj_tester
Also, any idea how I've done this? Would like to not do it again. The headset's been on the bike for 3 years and thousands of miles.