Got the new collar/washer from autopts, had time today to assemble and see what I have. Slop/backlash is same - 1/2 turn each way (no surprise). Putting the washer in the pocket didn't change it much. Now that the spindle is riding against the new collar, up/down play is really evident, so slop forward/back, and up/down.
Measured the spindle diameter. On handle side of groove, it's 2" like it should be, on D-jaw side of groove it's 19.77". Diameter of D-pocket is 2.013" to 2.016".
I talked to our in house machinist on Friday, he's willing to take a look at the D-jaw to see if he can (is willing) to clean up the face of the pocket. He didn't sound too excited about it. I know not to take anything off the outer diameter of the pocket, just clean up the face.
Am I correct in saying I need a new spindle to fix (reduce) the up/down slop? Then if I can get the D-jaw pocket refaced it just needs shimmed to reduce the forward/back slop.