Editing Hot rodding the HEI distributor (section)
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==Plug gap== Don't be tempted to excessively widen the gap. The correct gap is 0.035"- 0.040" for the majority of cases. Using plug gaps wider than that is unnecessary when using a basically stock HEI ignition. Wider plug gaps (or faulty ignition wires) cause voltage spikes in order for a spark to occur. This in turn causes the cap to fill with ionized air, and this can cause erosion/degradation to the components along with spark scatter and/or voltage bypassing to the distributor advance mechanism, shaft, etc. It is hard on the secondary ignition components in general and just isn't needed in the vast majority of cases. The large diameter of the cap helps to prevent this and it works well enough in a passenger car, even with the wider gaps that were used for some applications. But once the RPM goes up and the cylinder pressure increases, the chance of a misfire increases dramatically with a wider plug gap.
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