Great power, Greg, sorry to hear about this issues. Are you pretty sure that the idler pulley was what started the problem? I think you may have had a chain break, and then lost that bolt that holds the idler pulley in place. If the chain breaks, it can bunch up in the area of the timing cover and jam, putting some funny loads on the rest of the timing components. Is the bolt bent at all? Also take a close look at the front cover and see if it is cracked or broken around the boss where the stub cam comes through.
It may have been the idler pulley coming loose, though, those threads are notorious for stripping out. In fact the same thing happened to Jason B's heads, and I'm going to put some helicoils in there this weekend. Barry's idea for a stud there is a good one.
Were you running that sheet metal intake on the engine?