Ahhhh it looks like the theory about the HB was right. Glad it's such a simple fix. I also have a spare key or two laying around.

In the assembly of every cam/timing gear job I do, there's a couple things that are constants.
#1. A picture of the dots lining up. If those dots are lined up, your timing is correct.
#2. Always put the balancer on as mentioned by Gr8Racing said. That's the way it's done. Although I don't RTV, lube the bolt. I may start though. It's a good point.