Nate,
Thanks for the update on the changes. They look like they will be helpful.
Regarding change #3 above, I have found that the tensioning screw runs into the head of the flathead screw that holds the tensioner receiver to the main plate. On my machine, there is not enough clearance, and the countersink for the flathead screw is at the wrong included angle. In addition, the head of the screw barely fits inside the hole. This could be causing the receiver to strip. Were any of these issues addressed in the new part?
Thanks,
Robert