We are back together and riding, the rear end still has a slight howl but everything is within spec so outside of getting another gear there isn't really anything I can do. We're going to change the fluid at 500 miles and use Lucas 80w-90 in the hope it will quiet down some more. Anyway, here are some pics to further document our journey.
Here's the rear end out and disassembled for the second time, tech guy at Richmond Gear asked me to put .002" more pinion depth in it...
Here's the drive side pattern after adding the pinion depth...
Coast side...
Kid let me ride the Old Girl to work this morning
Had to ride over to another unit this afternoon to do some training, had to take a look back pic
