Yes, check with Jusride from Nevada, he's got 4 pulley's right now, going for his 5th to find the right one, and he's measured them all and knows them well! Give him a shout, and the dimentions you need, and I'm sure he'll have one that will work for you!
That should help... then make sure the plates and the tubes are in good shape inside the housing as you mentioned... and make sure there is little to no air in the system (try the two small holes on either side of the T-Stat trick to let the air escape) Then after that it may just be a fan issue? I have a flex fan myself, but a friend has a 68 350 H.O. and had a HD clutch fan, and hot running temps, went to the stock (for the 350 H.O.) 4 blade fixed fan, and all is good!? Could be that simple...
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