1. There are bad tight spots in the drivetrain, not knochy all the time but just tight spots. Will these improve with running?
Depends how bad it is? there may be some tight spots that will go with running in. As long as its not notchy, if it is, it may be because the bevel gear is shimmed too far and is clipping the diff plate.
2. The rear diff case overhangs at the back when attached to the chassis, meaning dirt can get in to it. Is there any reason for this? I'm pretty sure I have done front and back correctly, so it seems odd to me? I am planning to just tape over it but just can't see why its there?
Have you fitted the rear brace yet? the brace locates in that gap and covers it
hope that helps
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