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@Dammit
I'll take it apart again tonight.
No experience of integrated headsets (last one I installed was a traditional version, put in using the Murtle method of wood+hammer), I imagine the Park Tools website will have a full quide though.
If it was installed badly/headtube not faced/steerer not cut straight, what are the odds on the headset being banjo'd?
It did repeatedly loosen off, so it has been rocking under braking quite frequently, which I suspect did not help.