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Yeah, it sucks, but you gotta deal with it. I like to align it with the cover on, then take the cover off and before I start moving anything or taking anything else off, I use a paint marker to make a line on the sprocket and the block.
Also, don't be surprised if EVERYTHING lines up perfectly but the crank, and the crank will be off by like 1/2 a tooth. It's impossible to get that right. It's a proven fact that you will never get everything PERFECT because something will be off by half a tooth.
At the crank, it really doesn't matter two much because your crank spins twice for every one revolution of the timing gears. Therefore, if your crank is off by a 1/2 tooth, your cams are only off by a 1/4 tooth. You'll never notice, and neither will your engine. When that happens I like to retard the crank that 1/2 tooth. That way the cams are a little advanced.
Go forth and conquer fellow grease monkey! :beer:
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