Some HEI-equipped vehicles had spark plug gaps at .080.No it’s 25 on the spark tester… not sure what the units are. I think it’s meaning kV. Anyways… it translates to about .65 inches gap between electrode and cathode of the tester. Sorry for the confusion…
Keep in mind that .080 at 8:1 compression would be require way more voltage than at atmospheric pressure--although I don't know how adding some fuel to the air might change the ionization.
The HEI tester I like has a much larger gap than .065.
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The whole point of this testing is to catch an ignition (or fuel pressure) problem when the vehicle won't start. Testing it when it will start tells you nothing.
If this is really random--have you considered an ignition-switch problem? Intermittent contact inside the switch, providing power to some things, but--perhaps--not the ignition coil, or not the ECM?