Jeff; Sorry but I seem to have be not getting any of my notifications when post's I follow have new input. Had I been I would have brought up a few things regarding the clutch issues. At first I thought you had the motor mounts installed backwards for the FE and that would make the 3/4" issue with your Block/ball bracket. Honest mistake for some and causes issue with Tripower air filter top and the Hood latch. I looked at my project and can say we both have the mounts installed the same. I'm also very familiar with the cross shaft alignment. It has to be right or things at the pedal get Krazzy. I also know there are several Block brackets that move the Ball placement around as well as Frame side brackets. A mismatched pair or incorrect pair can cause your issue. I also know Ford has several different Clutch bearing forks. Again critical to system to have the right one. It's all about correct leverage. I have never had to put a chicane in the adjuster rod. The adjuster rod should be exactly parallel to crankshaft line. A 60 or latter Bellhousing has the Fork hole moved counter clock thus making the fork lower and makes the adjuster rod travel downhill. I suspect you've delt with all this but to me things just don't look right. As of yet I have not installed any of my Clutch hardware though it's painted and ready. The only photo I have was taken while I was building the Headers. Your Z bar looks to be correct but I'm wondering about your Frame side bracket and throw out fork. I don't think this photo will help much but maybe. Once the Smoke clears and I can get back in the shop I'd be glad to take you photos of the brackets with measurements if you'd like. Note the relationship of the Z bar tube to steering gear and frame bracket to Frame rail side. You can also see the motor mount position in bottom photo.