Help with identifying issue with Hub

Rune_T

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Hi

I have a bit of an issue with my hub. It's a DT swiss 240 EXP copy (Goldix 350) that i have converted to a regular star rachet mechanism. Beside the issue in the start that made me convert it, there has not be any issue with it.

I have replaced the bearings and the freewheel (with a original DT SWISS EXP hybrid freehub body) and all of the sudden the ratchet does not disengaged and surface near the seal has sustained some damage (see pictures)

It should be said that i'm a big heavy boy, but the bike has mainly be used for my commute.

Does any of you have an idea what have cause this ?
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My first thought would be a tolerance issue between the Goldix hub and the DT freehub body.
Sometimes everything looks compatible on paper until it isn't. I've had a few "DT compatible" parts that were just slightly off.
 
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