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Two, maybe three millimeters. Since it was hard to even look at it, I'm pretty sure it was too hot too touch. ;-) I'd have to say that was the most smoke I ever let out of a TO-220 case.
Two dead US 5$ IGBTs, a roasted solderless breadboard and a damaged gate driver later, I've got it working. One mistake was picking the microchip TC4423 driver. It inverts the input signal on both drivers for maximum hassle. The TC4024 has two non-inverted outputs and the TC4025 has one of each. I just ordered five of the TC4425.
With 100V charge into an 820uF cap, the electromagnet coil (stripped Ford starter solenoid - ~4 Ohms) I'm using will launch a computer case screw all the way to the ceiling. 8-)
Major design flaw uncovered. The SCR won't turn off because there is a DC path from the 12V battery to the storage cap. This won't allow the storage cap to drop (much) below 12V, therefore the SCR stays on continuously. I will now have to include a mosfet or relay to switch the 12V battery off after charging the cap. This is really a good idea anyway since I don't want to leave 12V applied all the time. It's just another i/o pin on the PIC to add it.
So far everything can withstand voltages in excess of 250VDC and the associated high currents, including the SCR.