Yes the roughed up cone will work but like you said it will soon polish out - but for a super light rotating assembly motor, it would allow real quick shift speeds - at reduced syncro life.

My thoughts too were about the energizing lugs, they wear and round over allowing less force being exterted - so I said wind a stifer spring/or you can replace them.

I can tell a slight difference in selecting 3rd then say 4th or 2nd - tiny bit less resistance (3rd has more wear on the lugs) unless thats just me thinking it is.

On a positive note, it seems that more driving is fixing the problem! It "sounded" like the dog gear skipped 5 or so teeth and now it "Sounds" like its only skips 1 or so - the crunch turned to a more of a instant dull click - hard to explain but its definately better.

Oh and the 1.6mm sounds huge but when I opened the box I noticed some else had been in it before (sealant, bolt heads) and theres new syncros all round! It may have crunched before and they tried to fix it, I dont know. They could have changed the energizing lugs for me too, sheesh...lol.

Nah, I was stoked with that and I did the bearings and seals.