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"the alum pulley might be 3/16 thicker , I would want 1" minimum between the fan & rad"I agree. You want 1" between the clutch face and the rad though...not the fan blades. If you would be using a fixed fan, then 1" from the blades. There will be some fore/aft movement of the water pump bearing as well as some engine mount movement. 1" should be a safe distance. I've seen some pictures where there was 1/2" clearance and the clutch kissed the rad. It didn't cause a leak but the fins were damaged.
You want to shoot for the blades being half in and half out of the shroud. However, if that puts you really close to hitting the radiator, you obviously need to move the fan back so you have clearance.
I'm in Denver, so I gets hot. I had dual electric fans and they sucked. They sucked big time. I spend a lot of good $$ on them and they impeded airflow. I'll mount the shroud next weekend. It cannot hurt, only will help in the long run.