I've been doing the 90-degree thing all along, I just didn't know how to describe that. All of the barrels slide onto the 51 frames so that they are just past the end of the water table, about 1/16 of an inch or so. About 1/16 of an inch too far, if you will. The 61 barrel and frame would only go together until there was about a .030 gap. After putting a little bit of a bevel on the end of the 61 arbor the barrel and frame go together until there is just barely interference if you try to turn it home so to speak. Not enough that you can actually see with the naked eye, but it definitely makes contact with the corner of the water table.
The wedge issue. Initially, when they barrel and frame would not go together all the way, the wedge was hitting the edge of the slot on the far side of the barrel. There was no question about this because it was actually starting to leave a mark on the corner of the wedge. Once I got the barrel and frame to go together completely and the wedge still wouldn't go through, I assumed that was the same problem. Closer inspection revealed that it's actually the tip of the little spring which sticks up too far, or is too blunt or something, so if I take a little tiny jeweler's screwdriver and push that down then the wedge goes through until the end of it is just flush with the outside of the barrel. It doesn't quite go far enough that the little clip on the spring engages the outside of the barrel. I figure overtime that will fix itself.
Don't know why I didn't think of the marker thing because I've done and read about that countless times. It does seem that the arbor is just ever so slightly bigger in the area where the wedge slot was cut. Not enough that I can detect with a caliper, but it certainly is rubbing there. I'll have to get some Emery cloth and dress that up. For now it goes together well enough that I think I can safely shoot it.
As far as I can determine the Arbor on the 61 is slightly shorter, like maybe a few thousandths, than the other arbors, both in terms of its length from the recoil shield and in how far it extends past the end of the water table, so I don't think it's bottoming out per se, although adding the bevel on the end seemed to solve the problem or at least help greatly.
One other issue I noticed that I don't think is causing a problem but just bothers me, is the entrance to the arbor hole on the barrel needs to be cleaned up. There is a thin "ridge" burr around the outside edge of the arbor hole, where they did not clean it up after drilling the arbor hole. It's around the outside, definitely not on the inside.