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I suggest that you send a PM.

Glad to hear you got it operational.

I don't think adding a washer under the nut would work, at least with a Shimano cable adjuster. I measure the depth of the recess on the back side of the adjuster at .48", almost exactly the same as the height of the nut.

Down tube diameters varied through the years so it's likely there were different lengths of the threaded rod. I would just cut what's not needed off with a hacksaw, then touch the threads up on a bench grinder. If you keep the grinding wheel spinning toward the cut off end, with the rod at a...

Try to get an idea about how much clearance you will need for the housing to clear the top of the rivet. You can file the head of the rivet slightly after installation if you just need a bit more clearance. If you need the rivet to be essentially flush with the stop material, you will want...

I have never seen anything placed between the boss and the frame tube. Anything soft would just make it more likely to rotate under load.

Bottom of seat stay or chain stay? A single rivet in the center of the stop from the donor bike might be enough. You would have to drill a hole in the stop. Before doing so, be sure that the nose of the rivet tool will fit in there. If properly located it shouldn't be too hard to drill a...

That is a clamp on shifter mount. I don't know the diameter or whether it was intended for stem mount or what. If stem mount it might be close to the right diameter. 4 mm is a fair bit bigger than 1/8", but some 1/8" rivets might expand enough to grab hold. 4 mm is about 5/32". There are...

The idea of the small diameter pin is to keep the boss from trying to rotate without relying on the concave profile to do that function. It would be more important for down tube shifters than STI but I would prefer to drill a hole in the down tube for it if it were my bike. On the CAAD2 frame...

I am wondering if you could drill out the rivet farther forward on the stay and use that as one attachment point for the stop. You would have to drill another hole but they would hopefully be far enough away from the existing hole to avoid stress cracking of the stay. Another option would be...

It's not something I have needed to research. When I looked at my 1987 frame, it had a 2 hole stop, with the holes perpendicular to the center line of the stay. Is there enough material in the stop you removed to allow you to drill another hole to match the existing hole in the frame?

Nice work. Looks like a pretty big lathe. What size and brand?

By high gear do you mean the largest cog? That is actually the low gear - lowest gear ratio with a given chain ring. I can't see what model of derailleur you have but it looks to be something like a GS cage Shimano. I'd need to know model number of the derailleur and the tooth count of your...