27motorhead
Old School Grand Master
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If I'm not mistaken. Don't you just need "tooth" clearance only with the derailleur arm/hanger? As the chain wraps around the other side of the cassette (back side)? So you could use your 34T? With anything cargo related you'll be happy with the biggest range possible if it's hilly.No clearance. The 6-speed cassette I removed had a 24t against my new 34t cassette. Dug one out with a 28t and I think there is plenty of clearance left for the chain.
OR you could slot the hanger to gain you some more clearance as shown in pic below? Doesn't have to be fully slotted as pic, just an elongated hole/slot would do and could be done with a round file in minutes... 2 minutes perhaps?
Loving this thread, you can almost picture what was going in Mike's head as he was creating this bike as everything is bespoke/adapted which means you have a reverse puzzle on your hand and having seized things certainly doesn't help. This thread will save other people a whole lot of hair pulling (if they have any left!). Thanks for the detailed posts!