pics of the freewheel mounted, but not down all the way; the cog hitting the frame; a fixed cog fitted; the freewheel off the hub; and two different diameter freewheels.
Here's my take. It looks like what I suggested: clearly, the freewheel isn't screwing all the way down the hub. I haven't tried installing a freewheel on my hubs, so I'm not sure what happens when you do. However, this was intended to work by the manufacturer. I will try this myself one of these days, but I don't know when I'll get around to it.
So Vic, I'd suggest getting a steel lock-ring and try to screw it down with the proper wrench over the full course of threads on the hub without the freewheel or cog on the hub. You won't be able to do this with the alloy ball-wrench ring S-A supplies. Alloy vs steel isn't happening. The hub threads might have gotten buggered by a loose cog/lockring on the hub while in use. ???
If you can get the steel lock-ring all the way down the threads on the hub (hopefully cleaning up the threads toward the dust cover) the freewheel should make more progress down the hub and clear the frame.
Anyone: would a bike shop have a die that would fit the hub threads?
I have never run into the freewheel diameter difference, myself. What would the other be used on? Freewheel hubs are all the same in my experience, so I got nothin'. Anyone?
I hope this helps, and I hope there might be more help from out there.....
Good luck, Vance
