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Hi Ed, I had the same sort of issues with the bellhousing, but, I expected it going in. I'll try to best answer things as I saw them and did them.
1. I think this is mainly due to the fact that they make the bellhousing the same every time, but with varrying years/models of the FE, there is bound to be slight differences in block casting, so you have to expect there to be some alignment issues there.
2. That got me the first time I installed a mcleod. The second time I learned from my buddy Fred Hamilton, who used allen head bolts instead. Perfect!!
3. I only had one plate. As for dialing in, I used the weld in guides (I don't remember what you call them) which requires you to drill out the pilot holes so that you can move the bellhousing into proper position given your dial indicator, and then weld the pilot holes into place. Worked really nicely.
4. Not sure about this one either.
The other thing you will absolutely need to do is use the template (you can find it here or ask David Kirkham) to cut away some of the edge matarial to clear the Kirkham frame. Easiest to do this not attached to the block and certainly NOT after you start installing it in the engine bay.
Hope that helps.
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