I'm resurrecting this thread because I have some more info about coil voltage from a new source (ASE master automotive technician, former Sun Electric instructor and 15 years as a technical training instructor for a car company):
"I can tell you for a fact that if you give me 5 minutes with you, a car, and an ignition oscilloscope I could prove their statement 100% false.
Looking at an O-scope trace the only time the voltage will equal the total output of the coil is when the wire is open circuited.
Look at this waveform
https://images.picoauto.com/copwaveform.png See the tall vertical line in the middle of the pattern? That is the spark line, in this case it is taking about 18KV to fire this plug. Assuming this is at idle, if we were to snap the throttle wide open the pressure in the cylinder would increase which acts as an insulator, and the spark line needs to rise by maybe 40% or so to let's say 25KV to fire the plug during that period of wide open throttle. So if the spark line is at 100% of coil output at idle, where does that extra 7 KV come from? This right there proves their statement false.
Next look at the almost horizontal line extending to the right of the spark line trending downwards slightly and ends with some oscillations. That is the firing line, and the more powerful the coil, the longer that line is. The less powerful the coil, the shorter that line is. In the illustration, that is a pretty healthy coil, the burn time is about 2 ms. This system can maybe throw 40-50KV if we were to open circuit a plug wire.
But electricity being lazy will only use the voltage needed to overcome the dominant gap in the system, which is usually the gap at the plug.
When I taught scope classes I used to have a plug wire that was cut in half and encased in a clear plastic tube, so I could slide the two ends closer and further apart. Using that it was very easy to see exactly what happened when the gap got bigger or smaller."
-- and --
"The easiest way I can think of to explain it is to think of wattage. 1 volt at 100 amps is 100 watts. 10 Volts at 10 Amps is 100 watts. 100 volts at 1 amp is also 100 watts. Coil output is similar, only instead of amperage think of time. The more voltage required to ionize the gap, the less time the the spark will last. There is a finite amount of power in each discharge of the coil. The more voltage that is used to create the spark, the shorter the time the spark will last (shorter spark line) The extra 10KV never really existed. It is just power that can be used to either ionize the gap, after that any excess power is used to maintain the spark line (keep the fire burning)
some modern ignition systems are capable of 80-90KV outputs, yet their spark lines are between 15-20 KV at idle. where did all the extra voltage go? It is turned into a very long burn time to fully burn the contents of the cylinder.
I agree with you that you can open the gap with a higher performance coil, but as rich as LBCs run, it probably isn't noticeable as it is on a modern car.
yes of course you may quote me and if there are questions, I would be happy to respond."
Not saying I understand this completely--yet--but this seems to confirm my initial belief that the spark voltage is determined by the gap, NOT the theoretical output of the coil.