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Not sure if it's a viable option (no idea on the internals of the Vario), but are you not able to add some sort of spacers to bring the burrs closer together? My Sette came with a few spacers for tweaking that. I realise they're different machines of course!
mmccarthy-
There's a grub screw which you can use to adjust the burrs - with the machine running I can turn this and get the burrs to come into contact (judging by the Noise) Baratza say that this should occur on the setting 2-Q. This was how I used to have the grinder setup but even with this the beans are grinding not fine enough and inconsistent. Quite a pita at this point
Tenderloin
So I bought a new pulley and motor and now the Vario is back grinding but I cannot get it to grind fine enough - have gone through all of the threads I can see on this.
I have two options - buy some new burrs, fit and see if this works. Keep trying to find the problem.
Or
Sell it as it is to someone who might be able to find the solution.
If the Niche zero were available I'd do the 2nd without doubt.