George---There's a part of your post that sounds like it could be the problem:
the part about the rotor being about 10 deg. away from the #1 tower as the
points break. IF...you are writing that it's the leading or trailing edge of
the (brass) rotor tip that's this far away, then you'll want to find a tooth on
the bevel gear that puts the rotor closer to dead center when the points break.
(Yes, you'll get to play with the oil pump dog registration again)
It sounds like the spark is trying to jump to a cap terminal out of phase with
proper timing, thus the sputter and backfire.
(Advancing the timing by turning the dist. body doesn't do much, as when you do
this, it also opens the points sooner and cancels out the move).
Try the above. Sanity guaranteed!
Dick
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