Followed up with engine builder today, had an interesting take on the coil/ignition module. He said very rarely he uses factory ds2 boxes on anything above stock, simply because an aftermarket coil is useless because of the factory “driver” behind it. He said to take full advantage of the system it was an option he recommended to step up to a msd box. By doing so you can take full advantage of all the features an upgraded coil can advertise. Also you have the ability to retard spark feature at starting. It’s a viable option I must agree.

essentially I am in the boat where I’m not sure what caused it to not give me grief this weekend. Do I stick a fork in it and says it’s fixed?

 

The DSII ignition system is a good one when everything is working right from the ICM to the distributor. The ICM retards ignition spark when starting, the stator/reluctor, if in good shape and you have 0.018" clearance between the two, work well together.
There's no problem running the stock DSII on a "built" engine. It provides enough spark for any occasion. My opinion on the MSD stuff, et al, is it's a waste of dollars unless you're turning 7-8K RPM constantly...as in at the track.
Me? I have an HEI distributor not because the DSII wasn't working well, because it was, its because the HEI cleans up a lot of wiring the DSII has.

If all the connections between the two are clean and snug things are hunky-dory.

If you haven't done the blinking test light deal yet and are relying on the working tach for your ICM/stator results, well, ok......but I'm confused as to how the tach would work if your engine won't turn over at speed.
I would still do the blink test....but that's just me.

Just my opinion on your coil but it's VERY borderline....I would replace it to be sure.

Remember - you still have a ballast resistor wire that's history.

EDIT: Another thought on "slow cranking:" I would tend to agree with the others that indicated a "tight" engine/timing...and mebbe not enough poop - amperage wise - getting to the starter.

 

Um, you may want to go back a couple of years in this thread, to post #311. I had thought the same thing about the timing, but apparently it's not true:

https://www.ford-trucks.com/forums/1...l#post17731499


Back to the MSD idea, that may be a good one, if indeed it actually retards the timing during start. That should hopefully give you the reserve you need for reliable cranking. Is it a plug & play system, or is new wiring required?

 

 

Any updates? I wonder if the starter misengagement is a common problem with this type of starter. The engagement mechanism is different with this style, so maybe it doesn't line itself up with the flywheel teeth as easily as a direct drive starter?

Similar problem in this new thread, although he has you beat on the number of starters installed:

https://www.ford-trucks.com/forums/1...rter-help.html

 

 

Did you see this, from another current thread?:

https://www.ford-trucks.com/forums/1...l#post17774330


The link in that post has some instructions about taking a measurement and possibly adding a shim. Maybe your starter's drive gear is extending too far and bottoming out. That might explain the noise and some shimming could take care of it.