Ok, well I've has another look at the chainset and its defintely not warn enough to warrant replacement - compared to the other cogs, the outside ring which is the only one I really use looks identical.
Reading up on it a bit more I'm pretty sure it's also not because I need a short cage derailleur - this doesn't seem to me to have the capacity to generate this kind of fault. Also I still have a triple chainset so I'm reluctant to change to the short cage in case the day comes when I shift to the inner chainset ring forgetting I have it
I am more and more going towards this being a freehub problem tbh although it is a little odd that it wasn't apparent before I changed the chain, derailleur and cassette. However...when changing the cassette originally I did not use a chain whip, so tightening up the lockring I was doing it against the ratchet of the freehub, do you think this could have caused a problem? Also, is there any way of testing whether the freehub ratchet is slipping? Could I just give it a good pull with a chain whip? Not sure I could recreate the same pressure tho tbh.....
When talking about a bent derailleur, how much are we talking about it being bent before it causes an issue, particularly outwards. Mine is very slightly pointing outwards from the wheel, were talking a couple of degrees max though.
Andy, I did adjust the b tension screw to get the best contact I could between derailleur and cassette
Fossyant, its a new SRAM chain. The old chain had warn the cassette hence changing the derailleur and chain required a new cassette also.
Yenrod, when I say about bending it how it should be, my frame doesn't use a hanger, the derailleur just screws straight into the frame. The actual frame here was bent so the derailleur was pointing inwards towards the wheel, I had to bend it out again so the derailleur was as straight as possible without the chain catching on the frame when on the outer ring. This meant it had to very slightly point outwards, max couple degrees as above. When overhauling the hub I didn't actually take all the nuts off the axle and roll it on a flat surface, partly because they were on bloody tight and partly because I didn't want to lose placing and have to fiddle about getting the axle position right again
However with close inspection it looked as straight as many people would consider to be straight.
1 vote for rear freehub needs replacing, any advances?