Joined: Jul 2015
Posts: 7,379
Likes: 3,221
From: NW Oregon
Bikes: 1982 Trek 930R Custom, '91 Diamondback Ascent w/ XT, XTR updates, Fuji Team Pro CF road flyer, Specialized Sirrus Gravel Convert, '09 Comencal Meta 5.5 XC, '02 Marin MBX500, '84 Gitane Criterium bike
I'd think you may have a sealing ring improperly installed/crooked... even the tiniest preload will cause binding when one of those gets crooked in there... the headset bearings SHOULD be able to take SOME side-loading from the steering tube, before there is any notable resistance in turning! My point is this... SOMETHING is not correct, from what you've described! Take it back apart, and INSPECT EVERYTHING again.