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Can I just drive a previously installed star nut lower down the steerer tube or am I better off cutting the tube first and then installing a new nut?
Never thought it would be an issue to drive it further down, done it a couple of times.
Depends how careful you are, but apart from you’ll need to use long screwdrivers instead of the proper tool there’s no real reason not if you don’t accidentally smash it.
The starnut has no input in keeping your forks on the bike apart from loosely when building. The whole purpose of it is to allow you to set the preload on your headset bearings. From a functional point of view, once the stem is on you could throw the top cap and bolt away and there would be no need for the starnut until the next time you had taken the forks off the bike.
I've reused them when possible ... not having a proper setting tool it takes the hardest/dodgy part away .. once its in straight it's much easier to get in a bit further than getting it straight in the first place