Begining to sound like either the axle moving, or the carrier moving on the axle with all those bits of ali off the sprocket. If engine and sprocket lined up, something has to be moving when racing. The brake disc would limit axle movement but show up as poor performace out of corners and disc look blued due to getting hot. Check axle grub screws. Remove one and see if there is a groove cut into the axle rather than a clear circular mark. The sprocket carrier can move if not clamped up properly. The Tony kart type sprocket carriers need to be done (clamped) up before tightening up the sprocket bolts (also the disc brake carrier), as opposed to the twin bolt type that pinches onto the axle.
I have used slide engine mounts, they are the dogs dangely bits and it is simple to see if the engine is on straight. But are the engine plate bolts tight. The front bolts need to be much shorter than the rear ones or else they will bottom out in the thread. They may feel tight, but are just bottoming out. Countersunk bolts are usually required at the front. 8 to 10 turns is about the best/most you can get into a TKM until you start to get to the bottom of the thread. The clamp bolts do not want to be too long in the front as they will jam into the bottom of the crank case. About 8 turns should do it.
The slide mount chassis plate may need grinding where it goes over the side pod bracket. On Tony karts this bracket it over/around the chassis rail rather than welded to the side.
Hope this helps.
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