Everything is brand new: Reynolds Ouzo fork, Ritchey Pro stem, Cane Creek IS headset.
I just took it apart and cleaned the clamping surfaces nicely. The stem bolts are greased and the noise still happens. I'm ruling out the cable ends since it happens not just when I turn the steerer tube but also when I torque on the bars. CRACK with every hard twist. Tried various pre-loads, bolt torques, still get it.
Any more ideas? Thanks everyone.