Wow. Thanks for the detail David.
So first thing to confirm I used all the original loose balls in the rear and one could assume they are all the same size... BUT on principle, proper maintenance practice would be too replace them all, correct? If so I may do that.
They are really old course so it makes sense. (I wrench my own vintage bike builds and rarely don’t always replace old bearings).
Your data gives me confidence to clean up the shaft just enough to let it pass. I will go with loose bearings. More balls to carry the load (also my practice with bikes!). Thanks.
ADD: I can feel a small raised edge on the side of the groove on the shaft that was cut for the e-clip. Just a quick deburring with a fine file should do it. Amazing what you can see if you look.
