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I can easily take everything back apart and remove the front spring hanger to trim out the lower portion of the box to gain more pivot travel.

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It's a lot easier to just put a sleave on the bolt that pushes down on the top of the spring. You can use steel, aluminum, whatever for a sleave. I use heater hose. The rubber almost totally eliminates the Caltracs rattle. I am going to try polyurethane next.

I ran into the same issue with the front hanger (3/4" off set) when I did my Dart. I cut the bottom of the bracket off flush with the hanger bracket and still had to do a little grinding to keep it from hitting.

Yikes, I had forgotten about how that bolt head would be close with the 3/4" bracket but that is a lot closer than the original posters 1/2" clearance. If it looks like that then I guess its grinder time. I seem to recall that Calvert has different shaped plates available for this type situation. You might want to give them a call.

the spacer moves the rear back to gain tire clearance up front in the 1/4!

call calvert and take a picture and explain to them. they should have bell cranks that have enough movement for your application.

As mentioned the spacer is for tire clearence. I honestly don't know how much the bell crank moves, before I ground on the hanger it did show signs of hitting the hanger. It would actually be easy to profile the bell crank plates and not affect the strength.