"The KPA-500 transformer should be more than just a "hair" away from sides 
(step 6 above) as there are rubber bumpers and a ribbon cable between that 
should NOT be pinched. "

Over the production life of the KPA500 the transformer design, and perhaps the 
supplier, have changed several times.  The transformer supplied with my kit was 
significantly larger in diameter that the one shown in the assembly manual 
photos.  The only way I could ensure clearance was to shim the transformer 
before tightening the bolt and remove the shims afterwards.  There is very 
little clearance, perhaps 2 cereal box thicknesses, but I didn't record the 
shim stack.

Andy, k3wyc
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