D27 Powerlock Install

So I did some test fitting of the empty case and found the holes line up a bit easier in a specific orientation..... reassembled and tightening everything down bit by bit, and it seems it's getting too tight to continue without concern of damage or striping threads. The two case halves are about 1/8" from what I think should be fully seated, but don't want to 'force' it - already been down that road. I know as the case halves come together, the Belleville disks and plates are getting flattened, so it's going to take some effort, but kinda wondering if I've run into another unknown/alignment/binding issue. For those that have built one of these, how much torque on the case bolts was needed? Part of the problem is tightening the case bolts is awkward as the case likes to spin and its hard to hold the case in place while tightening the bolts.

 

Does anyone have a picture of an assembled powerlock case? So in the pic above, is that as close as the two case halves get? The FSM discussed clearance between the cross shafts and ramps - I think I didn't (maybe still don't) understand how/where that is measured.

I should have put a ****ing lock rite in the existing case....anyway, that is probably what's going to happen as I've damaged this case a bit more...

 

FSM says it's 35-45 ft-lbs....but I had to go way over that to get the case halves together. But I think I see where I went wrong, but maybe too late to salvage.....still not sure what an assembled unit looks like and how the clearance on the cross shafts is measured. I think I got it way too tight. Anyway I definitely mangled sime hardware....where can one find the appropriate grade 8 bolts with the small hex head that I assume is needed for the ring gear to slide over the case?

 

Calling it good...used the standard size head on the hex bolts - so may need to grind a corner off a couple of those if the ring gear won't clear.....red loctite is setting up.
Nick - It'll be a week before I am back to the garage, but I should be able to pull the stub shafts, clean them up and send them back to you. The case can be set aside for a bit now until I am ready to pull the current case etc - I am assuming the internals won't loose their alignment sitting on the shelf.