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I'm running a 1.5" Pig FSA headset, 1.5" Totem, and a 1.5" Thomson 4x stem, and three 5mm interlocking spacers (one below the stem, two on top).

After nearly every run down the mountain there is a little play in the headset.

Yes, I crank down the top cap before tightening the stem bolts. Yes, there is a gap between the top cap and the stem (actually headset spacer that I'm running on top)....What I'm I missing?

I'm gonna pull the headset apart later, but everything was installed correctly.

An ovalized headtube doesn't seem possible yet, but I'll measure it with a pair of calipers.
 
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