i feel your pain but also had to chuckle in your 'play-by-play'. hope you found your wheel.
the tip on cutting clearance in the chassis pan is the one that worked for me...that and knowing that the smallest change in angle is going to hold up a start. i use a small folding table to give a chance to check alignment that 'leaning over' won't allow.
have you installed a flywheel with diameter smaller than original?
you have found there is a 'magic' alignment. good luck.
