True - I have now removed the entire cooling system - fan, thermostat housing and water pump - and re smoother all the surfaces on the block for when I replace a correctly fitting setup - took me 2 days the first time - about half an hour this time! :D
I know - dunno though, I'm kind of so ****ed off right now...It's a day for classics - not Pumas.
Heya Charlie - Killer and I considered that this solution might work - but because it is the 3rd issue I've had with this pump (1st - filing to go over the timing case, 2nd - 6mm metric fan bolts rather than BSF, 3rd - **** poor tolerance) - I decided enough was enough and I'm returning it.
Comparing the old to the new pump - now it's back off the block, I can report I make it to be about 2.5mm shorter than the original pump - plenty enough to leak!

