hi all...well your both right. firstly to make a precision bevel gear is a costly business with lots of expensive tooling, plus the fact the smaller you go the harder it is to produce, so redshift is right the gears are flawed they are not cut with multiple passes (as the correct procedure) they are a compromise between a correct cut and a cost effective gear. so cash rules there ...

also jerry is right that these gears where never designed to take a mm combo on 6s...

so you will need a bigger gear to take the extra power brushless will give out.
my personal experience is although these were shimmed it did noting to prevent chipping and wear. yes i run plastic cases but they are held with ally bulks so there should be no movement... but there is, i found the ally bulks have worn over the past few years and so have the cases,
fitting new cases still did not solve this as there is still a 1-2mm gap between each side of the diff casing.
this will be taken up by the expanding gears under power. so yes the gears are moving apart under power in this case.
so hybrid bulks are the solution with 8th diffs fitted to them...

bye all...