Hi everyone,
As you can see, I'm digging back into the beast again.

Got the head cover off and the only thing I found that was suspicious was one slightly loose injector. That gives me pause wondering if that injector could be my clacking noise. I never did think about simply tightening down the injectors.
* At idle, it sounds quiet.
* On acceleration it clacks like a valve lifter (hydraulic lash adjuster) is not pumping up.
* During cruise is clacks.
* At higher RPMs it quiets down again.
* Sometimes I think is runs quiet when the engine and oil are still cool. Not certain about this one - maybe the metal is cool and holding the injector better?
When I put this engine together a couple years ago, I used a lot of thread locker blue. Did that because I had found the crankshaft bolt loose. One of the guys said "...use gobs of thread locker..." so I did. Now, taking it apart, I see I should not have used "gobs" on the camshaft pulley bolts.

When I loosened the bolts, the thread locker was stronger than the camshaft pulley alignment tool and it sheared the end off the camshaft locking pin. As you can see here, the alignment marks are not aligned.
Here is a close-up of the thread locker blue dust.

Fortunately, proper alignment of the engine includes positioning the crankshaft to 90° to the right. This puts the pistons halfway down the cylinder so they are not in the way of the valves.
Dean.