There should not be any question on spark. It should be nice hot and bright. You might not see it in the sun, but certainly under normal shop lighting.
I'd say this is the area of your troubles, whether wiring or??
I laid the coil pack close to the metal surface this time as opposed to sitting high in the air and there is without question great spark there. As you said 'bright and blue'. I even tried a few coil packs to prove it. I am getting fuel up to the rail, I pulled the connector off before and it sprayed fuel everywhere and I can hear the fuel pump prime as well. I can only think that perhaps the injectors aren't seated properly? 6.1 rail on a 5.7 but still the original 5.7 injectors. Have seen it done before but I'm slowly running out of ideas?
EDIT: Well I swapped the rail back to the 5.7 and no different, it appears as though the injectors looked wet on the 6.1 rail, but never the less I'm trying anything now :banghead:.