You do get an appreciation for how well the original engines and all the internal components fit together and worked flawlessly for millions and millions of miles when weird stacked-up tolerance problems like this happen. I have built probably just under 100 Pontiac V-8 engines and I have never seen this problem crop up. But there it is and apparently Butler has seen it. Another little thing I will certainly check moving forward. I am glad the OP won't have a huge expense getting this fixed. A tough lesson for sure. My personal thank you for sticking with the Pontiac engine and getting it repaired so you can enjoy the car. It will be worth it.
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