Emergency!!!

I think they do sit very close to the edge but i havnt heard of them coming out yet.

um, ok it is hard to diagnose without it infront of you but I’ll try. Sound as if the first time the inner hub & pressure plate were askew with each other & needed a wiggle to drop the grooves into place. (I have one bike that loves to do this & you need to pull the spring posts toward you to get it to mesh to the plate, then put the springs in).

Either way try assembling the hub & plate together with NO plates. It should sit together in the slots & you can measure the min distance it can close up to. Then measure your stack of plates with & without the extras. It should be obvious that if the ‘without extras’ is smaller than the ‘No plates’ distance then you need extra plates.

But if not then the lesser amount of plates must grab & suspect the askew problem.

Of course with a thinner stack there is less preload on the springs, so will be more prone to slip so try adding just the extra steel (it should sit against the pressure plate ok but check).

The advantage of running thinner but more plates is that you have just increased the total surface area say ~15% per plate pair.

You got the "EP" kit. Same stack thickness (yes, you install the extra plates!), but more plates, each a little thinner than stock. I hope your basket and hub aren't notched. If they are, the new plate stack won't align with the notches and you'll have all kinds of problems.

As for your freeplay, it's normal to get a LOT more freeplay after installing new plates. Adjust it to approx 3-5 mm.