OK - I tried your test @rstucke - my measurement from the pressure plate being hand tightened to fully done up is 4.46mm...so it seems within your suggested range. I have attached some pics - the fingers seem ‘flat’ oncetight. @T1 Terry that link from samba is really interesting. It suggests a 215mm flywheel like mine should have a step of 22.73mm vs 24.66 for a 228 mm clutch as per @rstucke measurement above of 25mm and 21mm for a 200mm as per @Wayne murray ‘s numbers. So it looks like these specs might be right, and my step of 22.56mm is close to the 22.73mm recommended. So if we believe this my flywheel could be 0.15mm too short in the step (my measuring may not be that accurate I will go back for a second measure) is that enough to make a big difference in line with the problems I am experiencing?