Hi Mike
As you mentioned
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"I have seen the pump kit for the 235 conversion, I think the 235 engine is slightly longer than a 216 and the fan can be too close to the radiator in some vehicles "
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yes this is why I had to remove and press on a different pulley.
My experience doing the conversion on the 261 and 235 was that the block is not longer it is the extra 1/4" of the adapter plate plus the positioning of the and shape of pulley on the later 216 water pumps. The new or rebuilt water pumps that I was using all had the the narrow style pulley that I removed and replaced with the old style pulley flange and pulley.
As to the domed piston, ran into this when I rebuilt the engine on my HUP a few years ago, needed a new head because mine had some cracks developing, they had not leaked yet. The only NOS head I could get was for the flat topped pistons which meant I had to change pistons, not a problem as the cylinders were being bored which the pistons had to be changed. Pictures of the piston and head
http://canadianmilitarypattern.com/H...May%20Work.htm
Be careful of how you remove or drive on the crank pulley real easy to deform the hand crank boss. Made a tool that fit in the center hole and put the driving force across through the hand crank slots this way when pulley is driven on it doesn't damage the boss.
Cheers Phil