The spur issue is a little weird, you sure you have it built correctly as there should be no way the spur can hit the chassis?? A pic might help if you think you have it right.
As for the "crunching noise", what causes this is that there are some very small moulding flashes on the diff pulley flanges that just catch the belt as it rolls on and lifts it slightly. It won't hurt it and after a few packs it should clear up. However if you want to sort it either carefully smooth the pulley flanges. Or what is probably happening is the belt is not runnig dead straight, so maybe change the spacing on the idler pulley so it pushes the belt over a little, take a look at if the belt goes on to the diff pulleys straight and then adjust from there if needed.
As for belt tension just run the car, if it skips tighten it some more. Once it is set then it will stay as you don't need to remove the tensioner when removing any odf the drive train.
Hope that all makes sense!
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