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If you are taking about difference in backlash between the last comparison then all I did was move the thinnest shim from one side of the carrier to the other.
What changed? What's your pinion bearing pre-load? Trying to help but over the internet(w/ bad pics) makes it tough to help w/o 20 questions. I want to suggest hopefully you could contact someone in your chapter that could see what your doing and advise.
Do shops really do these things? -- Kinda sounds like using distilled water in a coolant system -- we all know it's the right way but find me a shop where you have ever seen it done...
The pattern looks pretty good maybe .001 too deep but it has good contact patch so I would run .008 backlash and call it done. .003 in carrier preload isn't going to hurt anything as long as u have enough preload.
You would be amazed at the gearsets coming out of the factories now. Had one just the other day with zero carrier preload as it just fell out out once I pulled the caps. Vehicle had 1200 miles on it
Still playing around to fine tune the pattern. The last 4 pics I posted seem to be the best it's going to get (with as backlash of 10). Nothing has really come close to that since. I was able to find a shop near me that is going to help finilize everything. I'll post final pattern and specs after to help anyone else doing the same thing.