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Interesting thread...
As far as pinning the distributor to the gear there at least four levels available:
1) the stock pin which can fail (the failure is almost certainly pure shear)
2) double pinning can be used; two pins are used one above the other (but not too close) and at 90 degrees from each other. Those who've tried it claim it works fine.
3) a hardened roll pin in the standard OD
4) a larger OD hardened roll pin; the diameter increase can be small so as not to weaken the shaft; a small increase in diameter will give a significant increase in shear strength. I have read about one setup where a 5/32" roll pin is used with a 3/32" one nested inside the larger one. The "splits" were 180 degrees apart. It replaced a 1/8" roll pin.
What flavor should be used? Slightly subjective maybe ;-)
Tom
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Wells's law of engine size: If it matters what gear you're in, the engine's too small!
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