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@crossedthread
Rather rudely, overlooked to say 'thank you' for all the feedback and help :-)
Really, really useful to understand actually how complicated this all is. When I took the Shimano cassette (cleaning up ready for the new block), saw there are three tiny thin shims. Guess those are what was used to get the spacing right for the mech - but as the shifting was never that great, more likely that was one of the problems!
Anyway, should have everything set up before next weekend so more news soonish.