Ok, back on the saddle after a necessary medical detour. Are there any details available on Oile's design? I would love to see them!!I I am a (retired) mechanical engineer and I am associated with the best private machine shop in Hawaii, may parts from the shop are in space, Nasa and Boeing are regular customers. No, there is no room for bike parts even though the owner is a big Harley and Britbike fan, it makes no business sense, BUT, with proper planning, I can get my own time on the occasional idle Lathe or Bridgeport, the only cnc that I could use was retired about 10 years ago. Modifying an existing gear is a big job, might even be impossible, The hub OD is too small to machine a reverse taper inside, it needs to be separated from the gear and reversed, most probably with water jet ( the shop has one), but I don't know how that affects the counter balance side, need to have one on hand to scan and turn into a 3d part in CAD before it can be verified. Yes, I have one in my driveway, but there are reasons it can not be opened at the time. I would really love to see Olie's design, whoever can contact him please tell him that I would gladly sign an NDA.That is a very interesting hypothesis. I actually have my primary apart at the moment and did wonder why the gears don't fully align. Could it be a simple screw up as you suggest? I also think the fact that the three shafts are not in alignment causes uneven thrust to the scissor gear as I have wear on over 180° of the main gear collar where the scissor gear sits. If I assemble them without the spring and shake them I hear a familiar rattle.
I have ordered a new gear assembly from Ollie Thiel, so may have a play around with the old one.