Replace the rockers with a set of 1.5's the noise and clearance issues should dissappear.
3/4 turn also.
You can not run 1.65 rockers without elongating the pushrod holes in all but the RA style heads.
The 1.65 rockers never came with d-ports and the castings were never designed to be used with them.
Most of your issues probably were a result of trying to use something that wouldn't work to begin with. Sorry.
All the noise, bent parts, etc, were a result of using a 1.65 rocker that increased lift and bound the pushrod in the hole or bottomed out the retainer on the guide.