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Thanks for the response, read through your blog post as well! Unfortunately I'm in Derby so trying your solutions likely isn't possible, but thanks for the offer.
It's an 11spd freehub, supplied with the 1.85mm spacer (which i shouldn't need). Got an 11-28 on it at the moment which - remedying the problem mentioned in your blog post I had with the 11-25 - no longer fouls the disc 'skin'. I think this was exasperated by the disc skin having no core, and thus running laterally out of true 1-2mm at points across the wheel.
The chain still runs extremely close to the wheel up on the 28t, might run some paste similar to engineer's blue onto an old chain and see if there's any observable contact. If so I'll try your trick of removing a sprocket.
Harry_C-
I think this was exasperated by the disc skin...running laterally out of true
It would probably infuriate me too, and more run out would only exacerbate my exasperation.
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might run some paste similar to engineer's blue onto an old chain and see if there's any observable contact
Stick a paper label to the disc skin and see if the chain marks or erodes it, much more obvious and much easier to clean up than bluing.
gbj_tester
I've still got my custom 10sprocket/11spd cassette and some 11-28s you can test if you're anywhere near west London.
Is it a 10spd freehub body? Do you have the 1.85mm (I think) spacer fitted behind the cassette?