It was the dreaded .491 vs .500 gear. I never experienced this problem before but since using a .500 gear the sucker fits.You might check the bottom of the drive gear for defects to ensure it will mesh with the pump shaft, and measure the length (height) of the gear as well as the overall length from the gasket surface to the end. It's not terribly uncommon to need some adjustment- I had to shim a Mallory once on a 350 "010" block w/hydraulic FT Comp Cam.
Not that it will necessarily solve your problem but here's a short read about distributor blueprinting and cam gear differences. https://www.chevyhardcore.com/tech-...ar-meshing-can-make-or-break-your-valvetrain/