well - I spent all afternoon carefully filing the ba$+@&ds down 0.5mm each, and I tell you - the aluminium they make those out of is seriously tough. Not the ideal solution, and almost sacrilege to file those lovely CNC machined bits. But when its installed you can't tell. I have waited months to get the Gemini going, and wasn't about to be held up by 0.5mm of metal.
On the plus side, they now fit like gloves, and I was able to get the mount outside to give it (and my new FS-60 reducer - thanks Louie!) a try out.
I ran the mount through a few worm cycles in PEMPro - and WOW

! - 3.56 arc seconds peak to peak periodic error!!! The best I had out of the old worms was 12 or so. Not bad for a 12 year old mount.
Took a few quick shots of the area around M7 to check out the reducer - seems to correct a lot better than the Tak flattener, and gives me about a 5x3 degree field of view.
Adam