Just for you Jim, here is the measurement of an original Ford head that has never been milled:
2.216"
The dist. boss and the stud bosses are the same. There would be a tolerance of a few thousandths or so from one head to the next but not much. Each counterbore measured .100 of an inch.
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Just to clarify, I never thought to measure the distributor opening. Doubt that my calipers would fit. Nor did I ask the machine shop to measure the distributor opening. So I can't add to the conversation. If required, a new distributor shaft of the correct length is simple to make. While the shop makes the first, I would just have them make up a spare shaft for the future.
The head stud kit was purchased from Bratton, not Snyder, so I would not know about the Snyder hardware. The various parts distributors may order their stock from different providers, so the measurements may vary. Attached are the caliper readings of the 3.5" grade 8 studs that were not used in the assembly.
Walter Bratton told me they order the head studs in bulk to be made up in kits. As of now, from Bratton's, the correct length grade 8 bolt is not available. The Bratton head stud kit does have a 3.75", grade 8, stud which was long enough for our purpose. But it is only available in the kit. I suppose you could order 11 kits to get 11 extra 3.75", grade 8 studs but.... Bratton did have the 3.75", grade 5 stud, available individully and sent me 11 of these at no charge.
It was determined not to compromise the integrity of the rebuild by leaving threads short in either the block or the nut. So the grade 5, 3.75" ignition studs were used in place of the 3.5", grade 8. The engine rebuilder assured me that grade 5 studs are regularly used in the much higher compression performance engines. (I am not competent to comment they accuracy of his comment regarding grade 5. Can someone verify the accuracy of that?) Using grade 5 versus short studs did appear to be the lessor of two evils.
At least with the Bratton ignition stud, care must be taken when using the longer ignition stud. The normal head studs have a shoulder on the course end which acts as a depth guide. The Bratton ignition stud does not have a shoulder on the course end. Over "snugging" the stud could place the stud too deep into the engine, creating other issues.
Right, wrong, or indifferent, that is what we did. The engine is back and I should get it installed tomorrow or Tuesday. Be great to get the truck back on the road as the roadster is a bit cold this time of year.
Appreciate all of the feedback.