Under star washers

[Alto Mare]

You should get away with a metal washer, but as you already know, I prefer a Delrin washer there.
Adam did a great job on the star, not only they look great, those are tapped to perfection. One flick of the finger and the star screws itself in all the way.

[Newell Nut]

I sent a Newell star to use as a pattern and Adam failed to use it so we have a problem that needs to be corrected. You can add more washers temporarily to make the SS star work but should not be that way.

[Alto Mare]

I hear you, but I personally rather have a Delrin washer there instead of a thicker star.

[Newell Nut]

Sal
The star was supposed to be patterned after the thinner P series alum star with a thinner hub as well. Just did not happen. The whole project idea was to replace the thick plastic stars.

I just went out and played around with my 540 and found that if I use 6 of the little wavy washers from McMaster then the SS Star works okay. Either use the delrin as you did , use wavy washers or use additional 3-18 washers and the star will work without Adam feeling much pain from his design.

I am satisfied that I can make mine work and get rid of the plastic stars.

Dwight

[Three se7ens]

I think delrin would be a good candidate for that washer.  I will have some cut next week, and send them out to everyone who has already purchased stars, and include them with the stars in the future.

[thinkwahoo]

Another option is to make some longer drag spacers either from brass tubing, or brass bar stock. This will eliminate the need for additional 3-18 washers or delrin washers. You still will need at least one 3-18 washer to keep the spacer from backing off the star.
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