Time for a bunch of spacer/bolt and "machining" information.
As mentioned previously, on the lower two bolts, the clearance inside the bell housing is tight. I needed to make some spacers, so I broke out the Dremel and files, aka "Redneck Machine Shop":
I used 10mm washers that I bought at Lowes. They only needed slight "machining" to get them to fit on the 7/16" bolts.
Even using my modified metric washers, the clearance inside the bell housing at the lower two bolts it too tight. The way the inside of the bell housing is "rounded" around one side of the bolt holes will not allow the washers to sit flat, causing the bolts to want to "cock" at a bad angle.
The end of the file is pointing at one of the areas around the lower bolt holes that needs "machining":
And again I broke out the "Redneck machine shop", aka Dremel, and used the below pictured attachments to "machine" the bell housing:
You do not have to remove a lot of material. This is more of a "sanding/polishing" operation. But, you do have to get aggressive to ensure that the surface of the bell housing is flat where the bolt head rests.
The lower hole near the clutch fork opening took the most work:
The other lower hole needed some attention, too:
Again, I did not have to remove a bunch of material. My total "machining" time, including making the washers, was around one hour.
A quick picture of my bolts/spacer stacks. Remember, due to the smooth shoulder length of the bolts, the bolt must be spaced back some, or you will mess up the threads inside of the adapter. The two bolts on the left are for the upper holes, the two bolts on the right are for the lower holes:
Before you bolt the bell housing to the adapter/front of transmission, make sure you install the clutch fork/spring/ball/throw out bearing!!!!!!
And the bell housing finally installed:
The lower bolt, nearest to the clutch fork opening in the bell housing, is still a little bit of a PIA to get to. The clearance around the head of the bolt is tight in some places, so you can not use a socket to tighten the bolt all the way down. I was able to start it with a socket, then I had to turn it with a wrench until it was tight. Once the bolt was tightened down with the wrench, I was able to get a 3/8 drive socket on it, to torque it down properly with the torque wrench. A socket headed cap screw would be good to use here, but all the places I went to yesterday did not carry/were out of stock on this size.
NOTE - there is still plenty of clearance inside the bell housing, i.e. nothing that spins will hit the bolt heads.
And a side shot of the installed bell housing:
All four bolts are secured with lock washers, and red lock tite, torqued to 45 foot pounds. There is close to 1" of thread engagement in the adapter plate, should be fine. If the lower two bolts were longer, then you could also use a nut on the outside. But, that would take a custom bolt, with the proper shoulder/threaded portion length.
Up next, hopefully soon and trouble free, lets bolt this damn thing to the engine!!!!!!!!!!
That's it for now.