I would have to agree there is a alignment gremlin. The only movable object that could possibly be off would be the oil pump. or
I am wondering out loud about putting gear paint like used for checking gear patterns. put some on the distributor shaft gear. wondering how deep the cam gear is on...
Question
Does the big cap unit fit just fine with no shaft? wondering on tolerances also even though you have checked.
There is no way you should be forcing a distributor in they should slide in nicely. But if there has been force applied there should be marks where it is hanging up.
I have a...
As posted locate the fuse block. Using a test light check each side of each fuse for power coming and going. If all is well locate the light switch is there power there? If not track it back towards the fuse block to see where it got lost.
If there is power heading out of the light switch then...
spacers are not a good idea all like posted it creates stress on the studs that may have been compromised previously.
Better to buy the correct wheel width offset to match the situation.
Usually the cylinder hone is not going to remove much metal just put a good cross hatch pattern in the bore.
There are other sizes of cups available and usually can find one a tad larger if funds are tight.
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