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  • Could I stick a washer / spacer on the hub body before putting the cassette on? That would push it over enough...

    Not a good plan because a: the lock ring threads will have less engagement, and they are hardly over engaged to start with and b: the chain will probably hit the dropout when you engage top gear.

  • It's very unlikely that i'll ever "engage top gear" but the lock ring could be a problem.

    So... will a new hanger solve the problem?

  • will a new hanger solve the problem?

    Well, a modified hanger might. You could probably mill a bit off the dérailleur mounting face. See if you can obtain spare hangers to fit your frame so that you can experiment and still have something semi-functional to revert to if it all goes horribly wrong.

  • will a new hanger solve the problem?

    inverse shim

  • wont a spacer on the hub body before installing the cassette work? dont know how much "play" you have on the hub body but if the smallest cog still has enough engagement that could work innit?

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