Was the 7spd cassette and 9 speed chain driven by parts you had on hand or was 
that on purpose?

I run a WI Eno 45t front with a cheap Shimano 8 speed rear cassette, altus rd 
stock, 8 speed chain for over a year now with very clean positive friction 
shifting... That's with a Riv silver shifter by the way.

I feel your pain, it's frustrating setting up a new system on a bike when 
you've really thought it out, bought the stuff and just can't make it work 
right.  Maybe take a couple days away from the bike if you can and approach it 
fresh.  I agree with Steve and Patrick that an 8 speed chain and cassette are a 
decent thing to try as well as general alignment checks on the drive train.

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