wait wait wait, before you spend more do on these gadets. I had a similar problem....... With a mini starter too. I broke the outside bolt.......The starter was twisting a bit.....
1.We checked the timing and it was a little advanced so I set it at 16*-18* base.......32-34* all in...
2. After the first mini starter scared me a bit.... I tried a new Ultima mini starter(GM 1999-2000 suburban or 1500's for the 7.4 454) from Oreilly's... still got the clunking grinding noise..... I even tried a CVR High torque starter from Smiley's racing, no go.......We put the ol big heavy duty stock starter back on.... While cool It worked for a few days and started fine then we ran into heat soak problems after that from being to close to the 2" headers.... You go somewhere then try starting it, ran into problems......
3. Then I tried the ford solenoid trick....worked great at first, one start, two start, third the starter stayed running........turned the key off, starter still running,had to disonnect the negative on the battery to get it to shut off.... Problem was the ford solenoid spring was not too dependable in shut off the power to the opposite polar terminal. We tried several solenoids....It even ran on while I was at Oreilly's......
4. So we put the car on the lift at my buddies shop and watched the starter when starting and we found even with the stock starter. The starter was moving slighty away from the flexplate, hence causing the clunking grinding noise........ We needed a starter bracket.....
5. So I came home, after a few beers, and 2 cigars later and brain stormed. I went to the Robbins Cheverlot and bought a starter bracket....... In the meanwhile DB electrical sent the replacement mini starter for the first PM300......
6. I did some slight fabrication to the starter bracket, drilled another hole with a 3/16th bit and also put some locking washers on the starter bolts....... 1 week later cars starts almost like a new car...... smoothe, no more grinding clunking, heat soak, etc..... I daily drive this car so it gets several starts a day..........
Also check your carb and tune it so you will have a smoother start and optimal idle mixture..... I idle around 900-950, 700rpms in gear.
I set the starter back to base, turned em all in and backed each one out 1 1/2 turns, then set from there.......Making sure If I turned on 1/8th I turned em all the exact same amount......
Bottom line you may need to tweak that starter bracket do to the fact that it apparently not keeping the startet from twisting...... It does not have to be much for the pinion and flexplate to be off, were are talking .020-.050 inches or even 1/8"........... What you can do is put the car on a lift, take a crowbar and hold the bar up against the starter bracket while starting it and moved it back and forth until you find the optimal starter engagement position, then tighten the bracket bolts. Thats another trick you can do................... I know the big block starter brackets are hard to find, the SBC or plentiful.... You can use the SBC but you will have to fab and drill to fit.........
I hope this helps,just throwing some ideas around with ya........:thumbsup: