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@benbrangwyn
If the ball bearings came in a cartridge, could be that the cartridge has fallen apart and is leaving so much debris in the races that at the correct tightness it's all jammed. Usually happens on the bottom race. I'm replacing a headset for a pal this weekend that's suffering from this.
It's important to get it fixed quickly otherwise there's too much stress on the headtube, sometimes even causing some ovalising on the tubing.
DoctorBike