So I cleaned up my parts and saw that I had a pretty torn up drive flange gear. I ordered a replacement from ebay. The matching gear within the final drive appears to be ok after cleaning and inspection. At least I really hope so since it's real hard to see down into that gap. I felt around with a dental pick and it appears smooth.

I then removed the wheel bearings and ground down the lip that resulted from not having the nylon thrust washer installed. It turns out to be about 0.034" of wear down from the original surface. I ordered two replacement nylon thrust washers and will double them up upon installation. I'm really hoping they're about 0.034" thick. If not, I can sand them down to fill that gap. I'm hoping that the compression from the additional nylon isn't significant under load. I guess I'll have to stop power shifting. And eat more salad.

You can see in this pic where the bearing edge is riding high even after being fully seated in it's cup.

Now onto the Progressive 416 air shocks. Does anyone have an idea where a seal kit can be found? I've scoured the inter-webs to no avail. Progressive (true to form) hasn't responded to my inquiring emails.
At least I really hope so since it's real hard to see down into that gap. I felt around with a dental pick and it appears smooth.
that is confusing to me. What you need to be sure of is that the teeth (female splines) are not excessively worn. If they are worn and the flange you bought is a little worn, that wear is not compatible, its compounded and the life of those splines is not going to be as long as it should be. I dont understand what you mean hard to see and feeling smooth.