*was this encounter a high risk of passing HSV2 if he had it?
No, it was not. A single protected encounter that lasted a very short time and you have HSV 1? Very close to zero risk. Don’t go there
*does this sound like a primary hsv2 outbreak for someone w existing GHSV1 and the supress meds just held it off/tamed it?
No, it does not. Condoms reduce transmission from men to women of HSV 2 by 96%. This just isn’t likely at all.
*would a sore show up same spot as original primary for new primary?
I don’t know the answer to that but I don’t think this was a primary, if anything, I suspect a recurrence of your genital HSV 1
*can repeat OB of G1 cause headaches & tiredness?