Well, it is sounding like an ignition switch. Just talked to him again, he said the terminal block isnt used. When we re-wired it after the rebuild, the hot wire coming off the key switch is going to the same post on that terminal block as the coil wire. So basically were are just using a stud on that block for a connector.
And he did say that at one point, while doing a wiggle test of wiring, when playing with the key switch that the issue started again. But wasnt sure if that caused it, or coincidence.
If it aint the ignition switch, it has to be a connection at the distributor or something. But he said he wiggled the crap out of the wire at the distributor and couldnt get it to act up. And everything there is clean and tight. So my money is on the ignition switch. Some bad contacts in there or something cause to my knowledge the switch hasnt been replaced in the 20+ years he has owned it.
Worst part is, the carb has been apart and cleaned umpteen times and a rebuild kit the last time:mur: