Actually, your pattern is changing quite a bit. Your first set of Pics was the best pattern by a long shot. First of all, your pics are mostly showing the "coast pattern", which is of secondary importance. The "Drive" side of the tooth is the convex side and the coast is concave. You don't want any sharp cutoffs in the pattern. A sharp cutoff is an area of stress concentration and a possible break point on the tooth. Your first set of pics have a nice start point off the toe of the tooth, and the end of the pattern has a nice fan out of the pattern toward the heel but still on the tooth where there is plenty of "meat". All your other patterns have sharp start and cut offs. In an early post it was suggested, that you load the ring gear more to get a cleaner pattern. That would be a great idea as well. apply load with a pry bar to the outside of the ring gear to the case so it takes 40+ ft. lbs to turn the pinion. That will clarify the pattern and move it toward the heal and make a better pattern. Turn it both directions to get a good drive and coast pattern. I think your first settings with .008" backlash looked pretty darn good. Here are a couple of pics of a 9.3" Pontiac rear i did recently.
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