Doh, today I installed the ball bearings upside down on the top headset cup, so that's what was causing the rough turnage on the fork. I flipped it over and reinstalled it, tightened it down, and there's like 1mm worth of play on the fork since the star nut is not straight, there's a tiny gap on one side of the top cap.

Ridable? I'm talking like a SLIGHT movement going back and forth on the fork, you can't really even see the distance it moves, only feel.