pulleys don't line up?!?!

[Cobravii]

the spacer is same length as the stock. my next suspicion is the balancer.

[Drew Pojedinec]

With the crank bolt out, how far is the end of the crank to the end of the balancer?
The crank *should* be just a tiny bit deeper.

[Cobravii]

it was about 3/4 inside the lip of the balancer

[blykins]

Then something isn't seated.

The crank should *almost* be flush with the balancer.   

[Drew Pojedinec]

That is why I asked..... it should be 1/8 of an inch before tightening the crank bolt, and 1/16 or "dang near flush" after tightening.
I think one of the keyways is holding your crank spacer from seating all the way in.

If this isn't the case than it has to be the timing gear not fully seated (This is why I asked how close they were 3 days ago).  When I was building my engine, it sure seemed like it could be an issue if you don't custom fit the keys.

[Cobravii]

Ok, I took off the timing cover and checked the bottom timing gear and it only has timing marks on one side so that theory is out. I did dress the keys so the spacer and pulley fit on better.
When I slide the spacer on I have 1" of crankshaft left to fit the balancer on and when I put the balancer on the crank is approx 3/4 inch from the edge of the balancer.

I am at a loss. The spacer was new and is the exact same length as factory. I don't have a factory balancer to compare to. mynonly two guesses are the bottom gear is shaped wrong or the balancer is wrong.

[KMcCullah]

I'm thinking the harmonic balancer since it's a race style. Some of the additional width of the outer ring is on the pulley side I'd bet. So the mounting face for the pulley had to move forward too. Maybe. Lots of aftermarket stuff combined together has messed with me before.

[blykins]

Not the balancer.  I use a ton of that same one and haven't ran into anything like that.

You should have around 3/4" of crank showing after the spacer is on.  When you install the balancer, it should stick out past the crank just slightly.

[jayb]

Judging by the photos the crank sleeve is on all the way.  In that case, the only explanation is the balancer isn't pushed on all the way, or the balancer is too thick.  The balancer will often press onto the crank kind of hard.  Did you have to pull the balancer off with a puller, or did it come right off?  Is it pressing completely onto the crank?

[Cobravii]

the crank gear, the spacer and the balancer are on all the way. before I put the balancer on there is approx an 1" of space left on the crank. I'm thinking the balancer is twice as thick as factory. If it is I think my solution is to shorten the spacer.

[blykins]

How thick is your balancer?

As I mentioned earlier, I use those same balancers on almost every street engine I build.  I have never had any pulley alignment issues. 

[Cobravii]

The hub is 1.5" thick

[My427stang]

Just want be very clear in a question, did you measure the balancer bore depth (or thickness) (I think that is your 1.50 measurement) and does someone have a stock Ford balancer to do the same?

Sorta looks like the balancer is thicker in the center, I have never seen one hang over 1/2 inch like that

Also, is the amount "left over" the same dimension as the pulleys are off?

Last question, do the timing marks like up at TDC?  Just wondering if this is the wrong balancer altogether

[Cobravii]

All excellent questions....

The part I measured was the hub thickness, I don't know how thick a stock balancer is and the "leftover amount looks to be exactly how much my pulleys are out of alignment.

TDC does line up correctly.

I'm willing to bet the hub on my balancer is twice as thick as it is supposed to be. If it is I'm still thinking the easiest fix is to mill off the extra amount from the balancer end of the spacer.
I also sent an e-nmail to my supplier to see if he has seen this before or if I was supposed to make alterations but didn't know to do it.

[Cobravii]

Ok, so it is confirmed. It is thee balancer that is too thick.
The supplier is taking it back and hopefully he can get me the proper one. If he can't I am in the market for a good quality balancer. Does not need to be SFI

Thanks for all the input everyone.