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Well done working through this methodically. Always hard when there are a multitude of problems. Only way is to solve 1 at a time. You are learning much!
I got the same setup as above too. Stock 7 (or is it 5?) blade fan on a HD Hayden clutch and only about 3/4" between fan and rad core. Early B's k-frame sits engine more forward than later models (makes engine to trans bolts easier to remove!). If Aluminium rad sits rearward core face further...
That nick will do next to nothing to the strength of the axle which is by design incredibly strong. The only issue is the sharp edges of the nick that could act as stress risers for fatigue failure at some point in the future. I'd file down the sharp ridges and run it without a second thought.
You are likely to have heat issues with your power steering hoses too as they were not considered in the design. My return hose is near touching the exh manif so a heat shield is required!
My brake pedal was drilled for both power and manual brakes so that was easy, but I think I had to mod the...
I would not do anything until I was 100% sure my TDC mark is accurate. Easy to do with a piston stop in No 1 spark plug hole, mark TDC centre on balancer when on stop from rotating both ways and actual TDC mark is exactly in centre of 2 marks. I had similar issues to you with a 413 I rebuilt and...