[Outwest34au]

"and found the wrong dia pinion bearing was fitted therefore allowing pinion to float which also added some unwanted metal"
I read that as wrong bearing, it wasn't specified it had worn down a size. Anyways, I agree the tailshaft should be closely inspected for phasing as you mentioned earlier AC460, good to do it in situ, then on a bench. I just really believe it would have been like a dog with 2 wooden legs if it was the shaft bad enough diametrically and Kyleb would have felt it on the 60km trip.
If we had a visual of the metal bits that came out it might tell a story. 5 internet points for every tooth LOL.
Since all my components and angles aren't as my kit make planned it I hope I don't have similar issues, I have only done 600 metres or so on the road.