Don't know if this method was discussed here already, but if memory serves me right, I think it wasn't.
Anyway, after endless hours of trying to fix the damn thing and even more hours on the phone with part-dealers (to no avail sadly), I finally managed to come up with a satisfying solution.
I took the black plastic wheel off the disc, sanded the disc's edges and glued the gear back on with thin CA-glue, trying to get the smallest gap possible.
I then took another (split) wheel and with a very sharp scalpel cut out a piece to roughly fit the gap of the one to repair.
Long story short, I put the cut piece in, CAed it into place and after some more sanding, cutting and adjusting, I put it back into the WM. What can I say, it works!!!
I fixed 4 DDs already using that method. The "clack" sound is gone and after re-greasing and re-adjusting everything they run like they're new.
Superb effort.
Also, you know you have some dirty ladies on you image hosting site :-)
Oh...hehe, pardon the ladies
