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Join Date: Jul 2007
Location: Minneapolis, MN
Posts: 250
Bikes: '86 Trek Elance 400; '83 Trek 520; 90s Specialized Crossroads, '84 Trek 610 (wife's), 90s Trek Multitrack (wife's), Cargo Trailers, Burley for the Kids, WeeHoo Trailer
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zzyzx_xyzzy - that was it exactly. The cassette and chain are new and the rack's screw was just a hair too long - protruding into the space right above the rear cog... just barely. This was enough to rarely catch the chain. I replaced the screw with one that was a couple mm shorter. No more problem.
Everyone, thanks for the help. I was focused only on the cogs and that wasn't the problem.