Listen to this noise...
Wow i have never experienced that before. This old dog might get to learn something again.
Al the converter bolts would have to be hitting the block exactly the same to make that noise that uniformly. (not likely)
BUT it could be a bent part of your converter dust cover bent into those same bolts.
This is actually a lot more common than people think when they remove and replace the cover. (you did say it has always done it)
Use a hammer handle or something like it (big screwdriver even) and while it's running and making the noise push on the cover in a couple of places and see if the sound changes.
It's a REALLY easy way to either eliminate or prove the theory.
Also the crankshaft and converter move a little when the trans is in gear, so the fact that it only does it in gear is kind of a dead giveaway that the noise is converter/dust cover related even if the bolts are not loose.
There is a rotor that is .030 longer that is supposed to reduce burning of contacts. Also your cap my not be seated in the groove. You may have the wrong rotor.
I run one of those rotors Napa part number MO300 and you are correct about the .030 longer.
It would normally rip the cap off if the cap was even slightly off center, and his sound is too uniform I think for it to be that.
