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You've touched on so many subjects all at once, I don't know where to start ;) This inlet timing thing is something that keeps on coming up though. I think Joey's 80 degrees ATDC is ok. Norrie wrote that book a long time ago. Like you implied with modern thinking, it could do with a bit more BTDC, p...
Sounds like a really good set up. That BGM 177 is a really high rpm quality kit. When combined with a 60mm Mazz crank its going to scream even higher. This is a good thing. Will never pull a PX200 gearbox, so forget that idea. As it will rev so high it should be fine with the 21/68 and a 36 tooth 4t...
Flat spots like you describe are usually due to running weak at low revs. If it has all the right jets then air is getting in somewhere. Usual suspects are one of crank oil seals, carb/carb box gasket or base gasket.
A lot of work you have done for what sounds like a jetting problem. What pilot jet is in it now? If is starts and ticks over ok then its normally just the big number of the pilot jet that is too big.
I expect the clutch would have been rubbing on the clutch cover when the nut was loose before it spun on the key and jammed. Post a picture of the inside of the clutch centre that you took off and we should see that it is a bit of a state in there around the keyslot.
Saw the video. Its just your crank moving in the main bearing. The crank should fit into the bearing tighter than that. Try it with a clutch tightened on and see how much float there is. At some point it has been running with the clutch nut loose and thats worn all the parts.