Bicycle Mechanics - New Frame, Play in Integrated Headset

New Al frame, all old parts, and after building everything up there is play in the integrated headset even when the headset is overtightened. My theory is that the chamfer of the frame is bad and needs to be faced so that the cups sit correctly and don't rock in the frame, but I'm worried there's something else I'm not thinking of. Anybody got ideas?

do frame and headset angles match? 36 degree? 45 degree?

you do have enough headset spacers right? also what kind of compression nut are you using? the new fangled kind that go into carbon forks can be a pain to get adjusted correctly...
just trying to suggest the easiest most common things first

Headset and frame match, enough spacers (and I also tried just leaning on it, no nut required), and Al steerer. Anybody got other ideas?

Headset and frame match, enough spacers (and I also tried just leaning on it, no nut required), and Al steerer. Anybody got other ideas?

When I built up the stickerless Bottecchia from BikesDirect that I got through the Holiday Group Buy, I had a similar problem. When I tightened it correctly, I had play. If I tightened it a bit more, it would not allow the wheel to turn properly but still got play.

In any case, I ended up putting a couple of the really thin (0.5mm I think) spacers that came with the headset, right on top of the bearings before putting the top headset cover on. I had only put in one of them at the beginning but adding an additional one did the trick. It worked like a charm.

I ended up putting a couple of the really thin (0.5mm I think) spacers that came with the headset, right on top of the bearings before putting the top headset cover on

BAM.... there ya go. i bet your headset cover is hitting the frame when you tighten it down.