So, after changing the internals on the headsets and re-tightening again we come to find that the star nut (or w/e it is called) keeps coming loose. We discussed that if it keeps happening that I would need to either have someone weld a "bung" above the star, or to try and find another kind of nut. The part that is in there keeps pulling off to one side a little (higher on one edge) and is causing the wobble w/o acting like it's loose by feel.
I cannot recall what he called it, but described it much like a three part quill nut. That the more you tightened, the tighter it got by design. He says it wasn't anything he was able to find any longer and that if I could find quality ones to order him some too. IDK, never heard of it and have no idea what he is talking about.