JC:

I just measured mine to be sure, and I also came out at 6 3/4 inches. Don't worry about that 1/4 inch (I didn't, obviously) as the cowl can be adjusted so it's not a problem. (IE: just move the cowl back a 1/4 inch.) It's not enough to cause any problems with the cowl and you'll probably also find it tends to fit a bit better because you have that 1/4 inch of play. If you feel differently, use plywood, but you really don't need it.

The hex bolts and blind nuts they provide in the kit are fine for mounting the motor mount to the firewall. (Look at close up of engine picture in other post.) I did find on my 2nd Patty they didn't put the engine mounting bolts, washers and locknuts they did in the first one I had. If this is the case with yours, go to your local hardware store (better, Home Depot) and buy a set of 8-32 x 1&1/4 inch bolts. They come with hex nuts, but don't use them. While your there buy a package of 8-32 Nylon Insert Locknuts, use them instead. That way you don't have to worry about them vibrating lose. Use these to mount the BME to the plastic mount. (Again, refer to the close up picture. You can see clearly where these go.) I believe the washers are #8's. There are extra in the kit. Do use blue locktight on the bolts holding the mount to the firewall with the blind nuts.

I'm finishing my work on the engine today (hopefully) and as soon as I put the cowl back on I'll snap some pictures so you can see how to cut the cowl out. One thing I thought of though, was what muffler are you using? I'm using the Pitts style and not the stock one. That will make a big difference when cutting the cowl out. If your not using the Pitts, then I'm sure I've seen pix here somewhere of the cowl cut out with the stock (or standard) muffler, so don't panic..I'll find them and get them to you.