Gave up. Epoxied the thing in place and ordered an old 600 series from Loose screws that I will put an 8 speed freehub on. It will out last me and my kids if they ever start to ride. The new and imrpoved stuff isn't meant for someone who rides 12 to 14k miles a year. It just doesn't hold up as well.
If I hadn't found this one I would have bought a Formula hub with radial bearings.