I did a little more homework today. On a flat surface the bar binds on the ball shank bolt and/or nut turning in either direction. Also, I am able to to get to that binding point pulling forward with my crummy turning radius tow vehicle.
I have some photos, but it looks like PhotoBucket may be having issues. I'll add them when I can.
Now I'm thinking I should use the newer head with the raised ball mount AND the 1" raised ball as the primary head in an effort to avoid binding. I suspect the ball shank will still need to be cut, but at least the nut should clear the bar.
Is there any reason to jump through hoops to keep using that older welded head when I have the newer cast one?

