Has anyone else had a problem with a big name converter nipple not fitting into the crank? I had to take nearly .020 metal (not paint) off of my converter to get it into the crank. This is a MAJOR convertor co (not cheap!)

NOt often but always check first.

I've had issues with them not welding the right size nuts on in-terms of having the snout bottom out inside the crank and then have to use washers to shim the converter back. But have not had an issue with a converter snout size since I was playing with an old 273 engine way back when. I would contact the converter manufacturer and tell them whats happened.

I have seen this happen. Problem was did not notice the problem and tore up a crank shaft and the main bearings. The problem was the crankshaft was not drilled properly. This was a big name crankshaft. When we checked the converter it had the proper diameter nose the back of the shaft was not correct.

Why does it hurt the crank and thrust bearings/main bearings if it is too tight??

I had this happen on a PTC converter. The guy I talked to said something about they were expecting me to be using a motor plate between the engine and trans. and if I had one their converter would have fit. So I returned it and they fixed it. Then the nuts were welded on slightly out of position and I elongated the holes slightly in the flex plate. Not what I would have expected from a first class converter, but I must say they hit the stall # and the thing works great after resolving these problems.

I had an ATI where the snout was squared off and it needed to be rounded over. It wasn't too long it just didn't fit the radius in the end of the crank.