I am wondering if you are over thinking this deal or expecting too much.
The noise to no noise thing is relative. On a stocker with stamped steel rockers and all the other stock stuff the valve train will be fairly quiet. This isn't going to happen with roller rockers on a warmed over engine. You are going to hear all kinds of strange clicks, etc.
You only want to get rid of the "clack, clack" clearance noise and then add your appropriate turn. Any left over noise is just the way it is.
What you describe is bottoming out the adjustment and turning it into a solid lifter. There isn't much room there. .050-.060? adjustment range.
Are you getting any oil to the top? If not, you need to get rid of the restrictors. That also may or may not help the noise concern.
Dave Koehler
www.koehlerinjection.com