Sounds Exactly Like A Problem I had.
might sound silly, but Have you checked to see if the splines on the gearbox are correct for the torque converter you're using?
In my case, a gearbox shop slipped me a 26 spline t/c when I had a 28 spline gearbox. I put it all together, thinking it would be like a Borg-Warner gearbox, and felt one solid clunk. With it all installed, nothing would turn over, and there was a small gap between the bellhousing and block. The t/c would spin fine by itself...