Originally Posted by wrobertdavis

ARGHHHH! I found the "problem". I had inadvertantly routed the chain over the little metal tab between the pulleys. Its a wonder the dang thing worked at all. The noise was from the chain bumping over this tab. It got louder as I moved to big gear combinations because the chain was getting really tight.

I routed it correctly and everything is running smooth and comfortably quiet.

Whew!

Bob