Those Aquilia 3rd gears were the nuts, i had 3 of them. But they only lasted a season till i'd b*lloxed them (i wasnt exactly gentle on gearboxes).
Quickshifters putting excessive strain on a gearbox? That comes from a person who regards them as witchcraft, and will never be convinced of their merits . They put less strain on the box, the better timing means much less load on the whole thing. I didnt use mine for a performance advantage, i used it because the gearboxes would last me about 4 times longer (did i say i broke them a lot?! Without a quickshifter i broke a new 3rd gear in 2 races at cadwell).
Pauls spot on about the undercutting, i stopped bothering on mine and never noticed any difference.
I'm assuming that was my old motor with the bent shaft? I'd have to ask: How did you do that?! Those shafts are beasts. I never had problems with that box, thats why it was never shimmed, didnt want to risk screwing it up, i had to use it so often after i'd broken the one in the motor Andy has.
Is Biggus still rebuilding gear boxes?