531colin wrote:Can you reproduce the fault on the workstand?
I imagine what happens is this
1) chain on small ring
2) mech. shoves chain against big ring
3) big ring picks up chain, but rollers rest on top of teeth
4) half turn of pedals later, chain peels off small ring at bottom run of chain
5) At that instant, NO teeth at all are engaged, so the crank can slip round under the chain and engage the teeth on the big ring.
If Im right, rotating the ring so the teeth are "in phase" should work.
When I look at the back of my chainrings, I can see wear where I habitually change rings at a particular part of the circle.
Do you see that? Thats the point where the teeth need to be " in phase" . I dont think they will be in phase all the way round.
NB point 4 doesnt agree with your "couple of seconds" for the chain to drop down, it would be much quicker than that!
Thanks again, Colin for thinking about it.
Yes I can reproduce it on the stand, just been out fiddling with it again!
I would agree with you about rotating the ring if I hadn't already tried that yesterday! It didn't make any difference. OK I've tried two of the five positions but can't think why the other three would be better. My second one was two bolts round, so phase difference to any of the other three will be v. small. Also, it works ok half of the time now, which is consistent with the 'out of phase' theory, but perhaps suggests that maybe I shift more at different points in my pedalling cycle and therefore can't solve the problem by aiming for the right phasing at one given point.
I think your sequence of what happens is correct. You are right, my couple of seconds is an exaggeration. It's possibly a third of a second, but a long time with a rattling chain!
What I did notice was how flat the ends of the teeth on my Impact big ring are! My middle ring, a TA (from SPA last week!), has much more rounded teeth. My other Impact seems to have slightly more rounded teeth on the big ring - although that could be wear as it has done a few miles, and my other bikes (an old Stronglight, a Shimano and 2x Truvativ chainsets) are all more rounded.
I now think that getting a different ring with more rounded teeth so the rollers have a bigger gap to aim for might just do it.
Edit - here's a picture of my chainset. The big ring teeth look very flat:

Much flatter than pictures of the Impact on Spa's site or ChainReaction (which I don't seem to be able to copy but click here
http://www.chainreactioncycles.com/Images/Models/Original/43350.jpg)