Tri_Joeri wrote:
What kind of shift ramp do you mean that was giving you issues?
rruff is referring to how the cogs are shaped.
Here's a close-up of a six-speed SunTour Perfect freewheel, a common design circa 1980:
Although some of the teeth are tapered at the tip, the cogs mostly have a very simple shape, almost like using a cog-shaped cookie cutter on a steel sheet.
Here's a modern six-speed Shimano TZ20 freewheel:
Notice how the cogs have more complex profiles. Not only are the teeth tapered much thinner, there are also areas where the cogs have "lowered" regions, and there are round pins embedded in the cogs.
This sort of cog shaping was introduced in the late 1980s by Shimano, who branded it "hyperglide." It has since become ubiquitous.
These shapes are the "shift ramps" being referred to. With the older-style cogs, the derailleur needs to practically rip the chain up and off of a cog and then drop in onto the next cog. Modern tooth profiling helps the chain "flow" off of a cog, and (especially on shifts to larger cogs) helps the next cog "catch" the chain and get it flowing onto itself.
The thing is, in order to work properly, the shapes rely on the links of the chain being positioned and oriented a certain way. This depends on the cog that's being shifted
from. The 28-tooth cog on that TZ20 freewheel is specifically designed to be paired with the 24-tooth cog next to it, and so on.
When you combine two mismatched cassettes to create a custom cassette, the cogs at the "joint" aren't necessarily designed to be paired with each other, and the shift between them might be un-smooth as a result. Sometimes it ends up working fine anyway, sometimes it doesn't.
This same stuff is true of chainrings. If a 50-tooth chainring is designed to be paired with a 34-tooth small ring, and you swap the 34-tooth small ring with a 36-tooth chainring, the upshift from the small ring to the big ring might suffer. It might not suffer, but it certainly isn't
guaranteed to work well.