Oh boy.. Not only did the place that pressed my cog onto the new shaft muller the gear teeth a little. They also mullered the gear a little more than I'd spotted yesterday by managing to bend[1] the thing a bit. So it now has a bit of a wobble. Life is too short to try to go through the courts and get them to pay for a knackered gear up kit and original cog that they don't make any more... so Mr Credit card has been pressed into action and a 2nd hand gear cluster ordered from a breaker. I may even find a specialist company that aren't a bunch of wankers to do the pressing on / off this time round. Meanwhile, I'm going to run with a (bit) bent cog and see how long it lasts. Muck [1] It has a little crack in near the centre too[2]. [2] As well as using copperslip instead of bearing fit type stuff.