I don't get any different performance from my 1100 horsepower dragster from .015 up to .055 gap.
Smaller gap is easier to fire in all conditions. My performance did not change from .030 to .054 in the Contour UNTIL it was foggy out or raining, then I would notice the motor slightly misfire under heavy loads with larger gaps. My son's turbo started running poorly and we replaced the wires for that exact reason. Gapped his much lower so the load on the wires wouldn't be a problem as quickly. All wires and plugs eventually fail or wear out, I am just trying to make sure I make them last as long as possible. No reason to waste money on parts. We do that enough already.
Anywhere from .054 to .025 will work just fine. I think the new spec is one millimeter from Ford.
Don,
The reason for wider gaps on modern STOCK engines has to do with how lean the fuel mixture is, especially at idle. It is more difficult for the atmosphere between the plug electrodes to ionize to allow the plug to fire. The wider gap causes a hotter spark to aid this condition.
The sutomakers pretty much know what they are doing when they specify a gap for a STOCK engine. There may be a little room to play around, but not much. No more than maybe .005".
The coils and wires are made for the gap specified and will be very robust for the application until the plugs get worn or fouled.
MODIFIED engines may be a different matter, particularly boosted engines. On a boosted engine, the ignition system often is not strong enough to fire the plug at the stock gap and the gap needs to be closed. If the ignition system has been sufficiently modified, the need is not as much. Hotter cams and higher compression ratios may also contribute to the need for a smaller gap, but not nearly as much as boost.
I'm speaking from several years experience as a dealership tune-up technician (and tuner of modified engines). I was the "go to" guy in town for any make modified engine when the modifications had been completed and they could not get it to run right.
The stories I could tell about straightening up problem caused by misconceptions about plug gap are legion.
So for nearly stock and stock engines, I completely disagree with you.