cadman

When I called them, I only asked about pricing for the module nothing else. it doesn't surprise me about the cost of all the other parts. Anyway, the module is drying in the box. Also even if all this works, this is an expensive repair just for bearings alone.
As far as cleaning all the other parts and taking the reel apart, I do a lot of reels for the members in my fishing club, family and friends. So if I'm not familiar with a reel I usually take a lot of pics. On the bearings, they seemed gritty even after I cleaned them and then put them in my ultrasonic cleaner. So I dumped all of them and put ABec 5's for the spool and carrier bearings and Abec 3's for all the others. The disassembly wasn't too bad, just have to be careful not to lose any parts and remember the sequence for re-install. I didn't take apart the module. If it doesn't work, then at that point I will disassemble it and see what I can find. If I can fix it then I'm money ahead, if not nothing gained and nothing lost. At that point I will buy another module. This is a good learning experience for someone that wants to learn how to fix reels if you have the patience and the skill set. Everything is back together other then the module. I will post results in a couple days once the module has a chance to dry up.

Yes use the finessse skirts from fishing skirts.com. They are thinner.

Clayton,
    Below is a pic of a Gami 3/0 604 hook in all the cavities. It looks like it will fit if you take out the center hook eye pin in all the cavities.

First of all I have never heard of epoxy melting a cup.  Next you need to tell us which epoxy(ies) you used, so we can help. I have been using Devcon 2 Ton (30 minute) for about 10 years and never had any issues. There is also a 5 minute do not buy that. Devcon 2 Ton (D2T) is self leveling. I use it on lead jigs and just love this stuff. Cures really hard, however on really white paint, D2T has a slight amber tint to it, however you can't tell on any other colors. Now my experience with D2T is that it goes on easier when it is warmer outside and levels faster. So your 90 degree temp days should not be a problem. If you apply it on crankbaits, you will have to put the crankbait on a lure turner, to keep the D2T from sagging or running. Other than that, it is a very good epoxy. Also you can put a drop of denatured alcohol in the mix, to make it more fluid, and more spreadable for a longer working time. If it takes you 30 minutes to coat a crankbait, you are taking way too long. I am thinking that you might get 20 minutes working time with D2T.
 
 
There is also a product called E-tex.  Envirotex lite. It is used for bar tops. It is a lot clearer than D2T, is more runny, needs multiple coats and in my opinion the final product does not have as a hard of a finish as D2T.
 
You can usually buy all the epoxies I mentioned from Hobby Lobby, or Ace Hardware. Also you can get D2T at a really good price from Tower Hobbies on the i-net, and they have the 9 oz bottles.
 
This is just my opinion. Others will have more info for you.

It is the 30 minute epoxy. However you will not get 30 minutes working time.

Matt,
    I am looking in their catalog and they have a whole buch of wire forms all the way up to 2oz heads. In their catalog, it is on page 107 in the 2013 catalog.
 
I also just went on their website, and if you type in wire and then look for looped wireforms, a picture of the looped wireform comes up, click on the arrow next to the picture where it says select. Then a whole pull down menu pops out with all the sizes . They are there.

No need to modify, they will work fine. The 38109 hooks have spring in them and they will fit fine unless you go too big. Let me know what size hook you want to put in what cavity and I will check fit for you.