Hi there, James,
Regarding the curved junction between the fixed jaw and the base of the vice, I believe the curve is to avoid the stress-raiser that would be the result of making the corner sharp. As others have suggested, a packer will usually overcome that problem. I have a short length of round rod with a flat machined along its length that I use.
Regarding the tee-bolts to secure the vice to, say, the vertical slide, there are two problems here. One is that the washers and nuts don't seat well onto the as-cast surface of the vice. I machined flats on the flanges of my vice base (think 'spot-face' if it were a closed hole rather than a slot). To deal with the second problem, I then attached the vice to the vertical slide and machined away the surplus lengths of the tee-bolts to make their ends co-planar with the vice. This included skimming a few thou off the nuts as well.
Please forgive me if the following constitutes 'teaching Granny to suck eggs'! When fitting the vertical slide and vice to the cross-slide, I grip a long parallel in the vice and, with the tee-bolts & nuts snug but not tight, I wind the vertical slide down until the far & near ends of the parallel come to bear on 1-2-3 blocks standing on the cross-slide each side of the vertical slide. This aligns the face of the fixed jaw with the cross-slide surface. I then fit a face-plate to the lathe and turn the vertical slide about its vertical axis until the two ends of the parallel are equidistant from the face-plate, then nip-up the tee-bolts & nuts securing the vertical slide to the cross-slide. If more precision is required, then one could use a dial gauge and mag-base on the lathe bed, turning the vertical slide until the dial gauge reading doesn't vary with movement of the cross-slide.
All the preceding paragraph refers to the case where the vice 'faces' the lathe head-stock – a similar but slightly different procedure applies if the vertical slide is to be installed with both its tee-bolts in the same cross-slide slot, i.e. with the vice facing either towards or away from the operator.
Best regards,
Swarf, Mostly!