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It is near impossible to set up many of these engines perfectly with the tool/ohmmeter/light, when there is a stack up of slop. A new engine is one thing, but a well used engine will have a sloppy mag plate, a little bit of crank clearance. Sometimes just tightening the point retaining screw affects the gap slightly. We do our best to make it perfect, but age and wear are working against us…
It is so frustrating to set it up perfectly statically, only to see things out of whack when it is running…. You can always go in through the inspection cover on the old flywheels to readjust slightly to compensate a bit for normal wear.