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I have a 1" spacer on my wheel. With or without the spacer my knees clear fine. Tons of room. I am 6'3" but I have a long torso. My jeans are 33" inseam and I wear long shirts and ties.
Different helmets add differents amounts. Bell helmets are the worst in this sense. They have a forehead hump the gives them the worst clearance in tight situtations. Look at a Bell from the side and compare to another mfg and you'll see it. I have heard this is an inch. I have a Bell.
The cost for doing the seat rail mod is unknown. There is a guy in New York that had his done in which I copied some pictures from. I don't recall his name.
If you want to get an idea you can call CFR welding in Connecticut. He has done something like this before and builds 911 cages all day long. He'll give you an idea. Top quality and price. Find a local Nascar shop and give him really good direction and they can duplicate it for $25 an hour as opposed to $50-$60 at a P-car shop. Make sure you warn them about the fuel lines running through the center tunnel. It's not a hard job. Grinding off the existing rails is easy and the only issue is getting the new pieces parallel, square, and in the same plane but it's not hard.
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