Just in case, I would check the alternator output for ac voltage and voltage drops from the positive lead to the alternator connection. Mine had some issues, and I added an extra positive connection to the underhood fusebox when I replaced and upgraded the alternator. Since the optispark runs off of 12V, I figure this could help.
I tested the optispark with a regulated 5v power supply, and it worked. It was a few months ago, so I hope I am remembering it right. With a clean power supply to it (grounded to the power supply of the controller), it could help eliminate any 12v entanglements.
I wonder if feedback was designed into the coil drivers like nissans do. One can hook an oscilloscope to a nissan's coil trigger signal and see a 5v representation of the secondary output. Kinda neat, but can cause problems if you are not ready for it. I suggest running your coil trigger outputs through a buffer IC with 8 input/outputs. I think the proper term is "unity gain amplifiers", but they will probably be sold as buffers.
Probably could use a big, fat capacitor right at the controller for anything else I missed.
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