I'm almost done with my engine swap, however I ran into a small problem last night. The battery post on my alternator hits my aluminum valve covers. I cut the post down enough to get the valve cover to bolt up, however it either touches or barely clears it. I know it will arc over when I crank it. I've read only two threads about this and no real answer besides new valve covers (not an option) and trying to rotate the clock which I haven't tried yet ( and doesnt seem to work for most people). I could possibly cut the post down some more, but it would require removing the nut that acts as the seat for the wire. Any suggestions? This is for a serpentine belt system

Too bad it's not an option... sucks to have some kind of valve covers you like, all ruined by a car that doesn't work...

Get some valve covers that actually fit. You'll be MUCH happier in the long run. Sell the ones that don't to the "greater fool"; trust me, there's ALWAYS one out there.

I doubt there are any tall valve covers out there that would work. These are even recessed somewhat.

What if I had a piece of rubber between the post and the valve cover. Surely someone has ran into this before. I do recall there being a plastic cover over the post when i pulled the old engine off. It wouldn't be able to arc through the plastic cover or so I wouldn't think.

You'll eventually wear through the rubber and be in the same situation.

Thats only if the stud touches the rubber. If there is a gap it should be fine. Even if there a gap without the rubber it'll arc if its too close. I'll think of something over the next few days and post my solution.

It won't arc unless it touches. You need something like 1000 volts DC to arc across a .005" air gap.