My thought is that the burrs for some reason might be out of alignment. This would cause problem such as what you describe. Apply some non-toxic paint to the stationary burr and run until they touch, and then check where the paint has worn out.
From online videos that I have watched I have always seen some slight variation in how the burrs zero out and touch around a full rotation, meaning there would be a slighter high side and not 100% even around a full rotation. So you may have them correct now (as they may have been before). I would continue to step down on your grinder setting until run out of adjustments or choke your espresso machine.I tore the grinder down again and cleaned it well. I tightened everything in a pattern to make sure it was even. Also checked to see if there was a wobble. There is a slight variation but after removing the burr and tightening again it doesn't seem to change. When I zeroed it out it you can hear the burrs touch but tell it's not perfectly even. I checked the burr and can see a line where it rubbed, maybe 1/32 inside of the outside edge on the bottom burr.
I did a test shot on 4 and it still came through in about 10 seconds. I'm thinking the beans I'm using are probably out of the fresh range at this point. I've been watching a few auctions on eBay. Think it may be time for a change soon.
Actually that's a great thought. I dismantled my machine a few months ago to remove the valve for deep cleaning since there was very little flow through the brew group. Also tore apart the boiler at that point and it worked well for a while. I know the valve is working somewhat though. Just backflushed the other day and was able to build pressure then it drained to the tray. Does that mean it is working normally? Or that it is worn out and replacing may fix issues?Check and replace your 3 way valve.
My Pasquini did the same thing when I bought it and the 3 way valve was shot
the 3 way valve releases pressure after the shot is done so you can remove the portafilter without getting sprayed. If it fails you don't get full pressure to the head
EDIT:..... WHY does the I and O keys have to be so close together......SHOT I say... SHOT!!!!! NOT...well you know
All ready for the new grinder, did a full cleaning of the espresso bar yesterdayI finally pulled the trigger on a new grinder. Got a good deal on a Vario refurb from Baratza.
Also got a baby twin for parts for shipping cost only. It came with the Silvia wand upgrade which I have swapped and also mostly fixed the leaking stream valve.
If the shots improve with the Vario I have a spare portafilter to convert to bottomless. I'll post back here once I get the grinder.