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Sam,
I believe the original screws were designed to bottom out before they actually tightened up on the gear. If the replacement screw is too short, it will pull the gear up tightly against the base plate, and thus make it hard to turn. Try backing off the replacement screw a little and see if that helps.
George
There are numerous things to do to restore tuners to their top function, washing with naphtha being but a minor one, check here: http://www.lutherie.net/tuner.maintenance.html That particular tuner, for example, may have a bent shaft, though it's hard to even guess without seeing them.
I seriously doubt the original screws were designed to bottom out before they actually tightened up on the gear. Adjusting the tension is important, but somewhat pointless if they're compromised in other ways.
It's physically and practically impossible to switch the worm from the opposite side, as they are held in place by riveted bearings. It is possible to switch cogs however.
Paul. the stuff that you have captured in your pages is pure gold. I didn't need to know that right now but I sure hope that I get to use it some day.
Mark
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