Yeah can't drop distributor in now as it won't fit with this intake. Not sure how to measure the dwell directly, will have to look into that.Hearing your description made me think of two things: point bounce and spark scatter. I think we can safely rule out the first one, and I can't remember the last time the second one came up. If the ignition is all the same as before, the distributor should be OK. But should is also one of my least favorite words lately. What about the oil pump and oil pump drive shaft? Anything new, different, or out of the ordinary with those? Do you have an old fashioned dwell meter you could hook up to a coil and check the dwell to see if it agrees with what you've set it to? Will an old school dwell meter even work with a CNP system? Does your EFI system require the cam sensor you've got to run, or could you drop a cheap distributor in just to see if it changes anything?
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