Re: new waterpump too big?
Yes. I have had this experience.
I bought a leakless from Bratton's when I got my new Brassworks radiator, in March.
There was a slip in the water pump box indicating that the impeller might need to be dressed-down a bit, to avoid grinding against the head.
If I remember correctly, it instructed fitting the pump up to the head w/o a gasket, and while holding it in place, to turn the fan-hub.
If dragging is felt, keep turning the hub several revolutions, while pushing-in on the pump.
Remove the pump from the head, and inspect the impeller to see where the high-spots are (will be rusty-red where it was rubbing against the hub). Carefully dress-down the high spots with a grinder, and test-fit again.
When the impeller spins free, install the pump with the gasket.
I had to dress-down the ends of the impeller-fins (the edge facing the firewall, as the pump sits on the engine) on my leakless.
I think it took two fittings, then all was good.
Over 1,000 leakless miles since.
Good luck with yours !
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