downhill headset... no particular reason, a rookie mistake so for mismatch alone, I am sure I will have to replace it

Yes, the large bearing goes on the bottom... I pulled it apart again & flipped the seal but it seems to be the same. With good compression, enough to make the steering stiff, I still have a minor "rock"

Maybe I did not tap the star nut in far enough and that could be compounding my problem?