Thanks for the info aavery2!! I hope you don't think I am accusing you of bashing as that is far from my reason for answering your post, or asking questions. I also don't want you think I am accusing you of creating the problems, and after your last post have no reason to think it was abuse of any kind. But you know as well as me, there are many who think they are doing right and are actually the cause.
I also am not insinuating that Lew's can't make a dud reel, I am sure they do have their share, and that is why they have a warranty. I personally would have contacted Rick and can positively state from working with him many times, you would have had new reels or at least they would have had any questionable part replaced once they were found to be in the state your telling us. No one in the industry has been better to work with than Lew's for me. Then if you were still sorry with your purchase recovered all your money for the hassle, and that is what I would have done the first year let alone 1/2 year. Like I said I was very interested in the cause, as my TP, the only one I have, is my test reel that I am using to judge the Lew's reels. I make sure it's not babied and not over serviced and a reel world test. I only own one because after buying the Team, like it much better and have 4, as well as most other models.
I am more confused now after you stated your findings, as the only thing to put wear on the end of the spool shaft is plastic on the tension cap side as they don't use a wear shim for a bearing surface like most, and to me this is an area I have been watching closely, as I would think the shaft would wear it and could be a quality issue, not vise versa, and I do think this is an area that should have been protected with a fiber or copper bearing surface, (shim or wear plate whatever). But it sounds like if it is not wearing out, and the shaft is what is wearing,,,, well why is plastic that tough and at the same time that abrasive to the Stnl. Stl. shaft???? On the other end is a fiber synthetic material that the shaft uses for a bearing surface to eliminate wear on the spool shaft end and I could see how the wrong fiber synthetic could be the wrong material for this. But it seems to be the same materiel some others use in this application without problems?? They use this method of end bearing surface on all their reels, that I have or have serviced. I am also baffled as if the shaft was that way from the start you would have surely seen or noticed it casting poorly to begin with, or if you serviced it from the start. I looked mine over closely when I first got it as that is one of the items I polish on tuning upgrades to reels, and when trying the different bearings to establish the quality of the bearings,I didn't feel it needed it when mine was new, and I will now definitely keep an eye on this area after your findings!! Like you if I find there is a need for a bearing shim in my reels to reduce damage and wear to the parts, I am going to say so, but so far I am surprised at the way they are holding up, but I do run very very little spool tension if any, on all my reels. The drive gear is an area I have been watching and if your wear is typical would be a real turn off with any of their reels. One thing I can only praise Shimano for, they are in my opinion the best producers of machine cut gears.
Thanks for letting us all know what to watch for as I am also not brand bound, and if I think there is better for close to the same money, I will be looking to them, I've done it before and in time will probably have reason to do it again, but right now that's not the case. I also find your choice of solvents and lubes very tasteful as they are nearly identical to mine.
I would like to advise anyone not familiar with the TSI product that 301 is a more of a solvent & treatment so to speak, and to never try it on plastics, and would be very careful using it on some synthetics. Thanks for your heads up aavert2!!!