OK, everything is starting to make sense now. With out the nubs, the ramp late did a real number to the drive face. It gouged almost half the metal out on the support walls. I put over 70 miles on it over the weekend. So, I'm guessing if it were left alone it would sheer off in 70-100 miles.
So, I'm putting this thing on ice for awhile until I can take the time to fix/replace all correctly.
Good/bad timing in that I am leaving for a 240 mile ride on thursday. Probably wouldn't have made it too far. :)
Still going to make the trip, but on my back up sachs... Wonder what the single trip record is for a sachs?
Thanks for the help all!