Ya the hei system was there before the rebuild and the module is new and the diagram was checked several times to make sure the right wires went to the right prongs on the module. Also yes we used a piston stop to find tdc. The cam was never degreed since at the time we had no idea it needed offset washer or have the timing set modified to degree it properly. I've thought of this maybe being the problem but I wouldn't think it would try hard to start if it was way off or the fact that on 2 occasions it did run miraculously and that the compression is at correct spec. My thought originally was that the valves were not opening and closing at the right times with the combustion process but I'm not sure what to think at this point. But can I have a huge vacuum leak and yet have perfect compression with no leaks in a leak down test? The exhaust and intake have been sealed with Remflex gaskets so I know I've got a good seal now so the other places left would be rings and valves leaking but those have tested fine. The spark was tested and yes it had a blue spark but it wasn't a huge or anything so heat wise I'd say we are on but the size of the spark may leave some to be desired. The coil is an accel coil so it should put out some good voltage.