I used the 5 speed fork and the long (27mm) carrier and it still doesnt work.

I measured up a few things and the ball the fork runs on is 3.5mm further back from the bellhousing face than it is on my 56 series and also I made my flywheel step 1.6mm which is far to big so I machined it back to 0.1mm (which is within the factory tolerance) meaning I machined off 1.5mm. This totals 5mm of "lost" length needed on my carrier.

Then to double check my workings I measured the distance from the bellhousing cover plate to the clutch spring and from the bellhousing face to the thrust bearing (when installed in the bellhousing) and I got 61.4mm and 73mm respectivly.

73 - 61.4 = 11.6 then I allowed for ~6.5mm freeplay for the carrier (so when the clutch fiber wears) and the number i got is 5.1mm (11.6 - 6.5).

This seems right so today I machined 40 ID, 50 OD, 5 Thick Hi-tensile "washer" to sit under the bearing to space it correctly. I'll let you know how it works - it should mean that when bolted to the motor, the clutch release arm has to travel about 14mm from fully retracted to touch the spring, which on a new clutch "sounds" and looks right to me (about a 3/4 to 4/5 travel left in the slot).