I agree with all you findings Michael H, I found pretty much the same. I arrived at a belt tension of abut 5/8" to 3/4" deflection at the lower mid point with a 10lbs push on the belt. A little tighter and the belt was noisy, less and it made a turbine like noise on acceleration. Alignment of the rear wheel and the belt are also critical, as you also found. I gave the belt and drive gears a good soapy water clean at the same time. I suggest about 15 or 20 ml. of Liqui Moly MoS2, or equivalent, in the bevel gearbox oil as well as it seems to have quietened my BB down a fair bit and cannot do any harm. We may sort out the last 10% of this kit car yet?
