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Brent,
For what it is worth it, sounded to me like you have two seperate problems going on as I read through this. First, the buzzing. I too think the bellhousing is not centered. Just out of curiosity, do your locating studs have a slot head in them or your bellhousing have a thick locating washer welded on?? Either of those would indicate the bellhousing was likely aligned(properly?). As I believe the bell housing wouldn't likely align to spec without some adjustment. Second, I too have an external slave and an inch sounds like enough throw. But, for what ever reason, you just are not getting enough throw. Is the central axis of the cylinder perpendicular to the clutch arm as it is currently mounted? Or is it cocked? Do you have a lot of play in the pedal that can be adjusted out? I would also re-bleed the line just to rule that out.
Good luck Brent, maybe take a bit of time away from the car and when you go back things will go easier. Steve
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