Thanks @FBinNY @hueyhoolihan and [MENTION=20548]JohnDThompson[/MENTION] -- I think you've hit the nail on the head re: troubleshooting. FWIW I think I've just had a string of difficult headsets/frames/forks. (I don't use retainers btw.) I'm going to keep working at it though. I'm not equipped to do the more involved fixes (facing, cup pressing, fork crown seating) but in cases where I just can't get it right I suppose I need to just bite the bullet and go to my LBS.