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the top hat washer holding the c/ring in place was not a perfectly tight fit, would say about 1/2 mm out, would that be enough to cause a huge difference in tension d'ya reckon?
What cranks chainwheel and freewheel are you using Daz?
chains do give, and like laz said, a two pice spider, no matter what make or quality, is never going to be coc'k on, and as alex said, freewheels arent built to be micrometer perfect, three variables coming together is going to cause tight and loose spots, no matter how good your builds are.cest la vieDave