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Well, the way I normally do this, I set the cams in their proper places (without having the belt on anything). Then I put the belt on and use a "quick clamp" across both gears to keep everything in place. Then I thread etc. (leaving the crank a little before TDC to allow for movement when tensioning up the adjuster).
You didn't by any chance remove a lot of material off of the head. I took off .020 on my NA and the alignment is a little tricky.
Funny thing is though. Usually when you are off a tooth the idle isn't smooth. Its rough like you have a cam in there.
MB
Also, just had a thought on something I have seen over the years. Is it possible that the dowel pin on the timing gear is messed up? Possibly slipped a little or "scrunched" (yeah a technical term, lol) a little during instalation?
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