I think I would try forcing the gears together (less than zero lash) with extreme pressure lube first before using an abrasive. Seems to me this would slightly crush the machining marks in the aluminum gear and give a bit more clearance when installed. Tom's suggestion to do this in a lathe setup would work well. Switch the mesh repeatedly (simulate a "hunting tooth") to equalize and also move the gears back and forth axially a bit for the same reason. Finish with timing marks aligned.

Have not done this. If you do, please post result.

Last edited by strokersix; 08/29/19 10:53 PM.