for my bike and my ears this was the ANSWER!
Originally Posted by
eflayer
somewhere else it was suggested that i isolate the headset cover cap from what is above it and what is below it. i made three "o-rings" or rubber bands by cutting a bike inner tube crossways. i stretched one over the circumference of the FS above the funny cap, one below the funny cap, and one under my three spacers. now each is isolated from what's above it and below it. will remove the tape on the rubber boot and give the new idea a shot on our crap roads tomorrow.
I think I finally nailed the solution to the rattle problem.