Quote:
Originally Posted by camaro1969
also, i have pin gauges, maybe 50 of them, one is a classic snap on one, maybe worth something now LOL..
ill keep you guys updated, i now owe, 2 beers (vegas69, 70rs) and a coffee(greg)

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Hey I'm the one that came up with checking the engaged clearance of the pinion gear in the first place!!

Just kidding. I'm glad you are on your way to solving the problem. I only mention the paper clip as most people don't have or know where to get pin gauges. The "medium size" is just a rule of thumb to get you a usable clearance.
I am however concerned with one of your statements. When the starter you showed first is mounted, the pinion should not be extended nor engaged without actuating the starter solenoid. If it is, I believe you have an issue with that starter. The picture you show in this link
http://www.transmissionadapters.com/...i%20torque.jpg is showing the pinion in it's retracted position for this type of starter. When you bolt it up, you should not have to shim it much to get the .100 clearance. It should absolutely not be engaging the flywheel. Can you get some photos? Unless I misunderstood, that shouldn't be.