Once again - many thanks Art. It resolved as I suspected. Had to lengthen the topmost "shaft extender" by about 1/2"-3/4". Luckily I had more than that much slack inside the spline (they're hollow) when I welded it on. Cut the welds, slid the spline out so that length of the shaft went from 5" to 5.625", welded, painted and reinstalled -- this time WITH THE WHEEL ON AND TIGHTENED DOWN. We're back in business. Perhaps I can drive it to get it inspected tomorrow! Pics below of the revised shaft and what the install looks like.



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82 242 6.2L coming...; '15 Honda Fit
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