Without actually being there first hand, and just looking at the pics, I'd say personally the contact pattern you've got looks fine to me. I say this because it appears that you've got full contact between the faces of the ring and pinion gear and the teeth aren't bottoming out. Rather they appear to be hitting at what appears like a proper depth with each other. That said given the fact they are straight cut bevel gears don't let the extra little bit on the toe bother you. I've never seen anybody turn the gearset that many times when setting them up. As many times as you say you turned it the 'problem' could be one tooth that isn't exactly right and the number of turns just makes it look like the problem is worse than it actually is. As a part of that train of thinking, just the transfer of the paint from one tooth to another on the first round would make that one tooth be higher than the others. From that point on it will just make the problem look worse every time that high spot goes around and hits and picks up more of the marking compound. Granted the depth they mesh also controls the amount of backlash but as long as it is within spec, or 'feels good' if you have no actual factory spec. All that said, if the gears have been running together for years, and you had them apart you can bet they will never run together again exactly the same as they were origionally. Too if they are new or used gears they will not run together exactly true from the start. Either way, given the pattern that you've got, as long as there isn't an excessive amount of backlash then I'd go with it.
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Today's Featured Article - The Nuts and Bolts of Fasteners - Part 2 - by Curtis Von Fange. In our previous article we discussed capscrews, bolts, and nuts along with their relative hardness and thread sizes. In this segment we will finish up on our fasteners and then work with ways to keep them from loosening up in the field. Capscrews, bolts and nuts are not the only means of holding two parts together. When dealing with thinner metals like sheet tin, a long bolt and
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