Nolan, Well done diagnosis. This has been an interesting (for the Forum) and frustrating for you issue. I also have no clue what size it should be in inches. I will indicate that there is reasonable and historic evidence that the replacement will be only moderately worn, and not a problem. I would measure the new components and if the difference between the two sizes is between .002 and .006 I would accept that as OK. When new it might be in the area of .001 to .002. (a guess based on sizes in other distributor drive gear to housing measurements, and reasonable expectations. Someone cobbled the gear back together with either the wrong key, or a chip of incompressible material under it. Poor workmanship. May the pulley replacement go well, and the distributor not wobble. In my experience, I would put it together with the good pump and new hold down bracket adjust the static timing, and tighten it up. Do not loosen the distributor ti "see" if it wobbles. Cam angle variation is the enemy. Use a timing light on the pulley with the pickup placed on several of the plug wires in succession. Look not for the timing mark, but for the image in the flash to be solid and not jumping around forward and back. The solidity is an indication of pretty good timing stability. A distributor analysis machine (Sun or other old machine that uses the distributor out of the vehicle) will be the best for accurate analysis of cam angle variation, and dwell. Call around to find one being used. An oscilloscope will also do it if the operator is an artist with it. Best of luck, the answer is in hand. Jim
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