Seeing this thread a few days ago would have saved me a couple hours tonight. I thought I was losing my mind.
Broke a bolt on my bedbar and, when the bolt broke, the bed knife made contact with the reel and made a mess of my reel. So I replaced the reel and bedknife from R&R. After finally getting the correct bedbar I put it all back together. Even backing the adjusters out as far as I could, the bedknife-reel contact made it impossible to turn the reel. I took everything apart and reassembled two times thinking I had something wrong.
That's when I started to think the reel was just a little bit big… and that's when I found this thread…
Put old bedknife on and, while there is still contact, I think it's enough that a good back-lapping should take care of it. Been a frustrating evolution to say the least but I sure learned a lot about how these mowers work in the process. So tomorrow morning I will back-lap and I should be good from there. New reel, bedbar, bed knife and grass shield. Along with new spark plug and air filter. It will be like a whole new mower.