Good eye Bruce, you may be right.
You have to push the chain rails on with your thumbs pretty good until they snap into the right position on the pins.
Here's a pic of my origonal passenger side chains before I removed everything and it looks like the chain rails may be around 1/8" farther on the pins than his are.
The plastic chain rails have raised grooves on them that line up in between the links on the chain and if it isn't on all the way than they will be out of alignment with the chain and maybe thats making the noise... hard to say from the pics.
And the driver side chain case with new parts on both sides: 964 cams from webcam, rocker arms, rocker shafts, chains, chain rails, cam sprockets, idler sprockets, and idler sprocket shafts.. while I was timing the cams.
You can see how much less extended the chain tensioner is with the new chain in the driver side pic.
The intermediate shaft sprockets looked good from what I could see in there with a flashlight.
I have no where to do it so I did it in my driveway with the motor in the car lowered around 6" in back onto a jackstand.
