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@Sanddancer
I've disassembled and reassembled the headset 3 times now, always the same. Nothing looks to be out of order when it's apart; no marks on the bearings, frame etc where it looks as though something could have been moving, rubbing or knocking. I've been taking it very easy on it until I can get it sorted. I think I'm going to have to pop into my lbs and see if they can do anything different.
Officially there are two frame, the Track and Fixie, though it seems from discussions in other threads, it's a toss up as to what you'll receive. Supposedly the Track has no drillings at all, though nobody has seen on without the drilled fork. The Fixie either has a small pilot hole at the rear that needs to be drilled out to take a brake or no horizontal drilling in the bridge, but a small one running perpendicular to the direction you'd expect.
As for sizing, they really are a lot bigger than you'd expect. I'm 6'6" and ride a 63" Roll, 60cm VN MIstral, 61cm Koga Record Pro and a 56cm 464!