Thanks for your Help. I fixed this yesterday and was enjoying the machine all evening.
The upper trip pawl does move with the circlip beneath it (because the circlip is tight on the shaft) and the weight of the upper pawl on this circlip does indeed Help it move before the actual lug does....but you're correct in that it doesn't matter, because as it gets near the end of the record the upper pawl tab will constantly get nudged back slowly with every rotation of the turntable by the edge of the flat portion of the gear - until of course, like you say, the record hits the run off section causing the upper pawl to be contacted directly by the flat portion of the gear, which in-turn starts the cam to rotate. And I say this for the benefit of other people like myself who may come across this problem - I am not intending to insult your intelligence or anything, I know that you know how it works
- I just hope it will Help other people who may come across this same issue.
I'm really happy with how straight I managed to get it. Not perfect, but perfect enough. There were burrs as well on the tab which I have taken out. The upper pawl just sits better now, it looks correct and it looks happy as it sits there awaiting its next trip.
I didn't do anything to the turntable gear. Looks like the whole deck has had lots of hammer to me though. I think the bent tab has caused the uneven wear on the ramped part.
When the upper pawl was bent then, it must have been binding just enough (even though the whole auto-trip parts/cam were rattling like a tambourine) to oppose the gentle nudging action of the end of the ramp/flat edge of the gear. Perhaps the burr was helping it grip too, adding to the problem. As for why it didn't work correctly when it was downstairs, I'm guessing the surface flatness (or lack of) actually showed the fault up more, so it's a good job it did really.
Anyway, thank you very much for your Help, it really is appreciated.