another option is that one of the wires you made up has a bad end, swap out another set of pre-made wires and see if that helps

[QUOTE=Mr Gadgets;2194508]Do you have the polarity to the coil from the box correct. Seems like if it is wrong that will do something (and I cant remember what) but I know it wasnt good for it.
QUOTE]

I believe you'd have less energy going thru coil. Maybe okay when less energy is needed, but show it's face (engine misfire) when more juice is needed. This is a vague memory in my part.

Typically, the button wearing down is either low grade button material or a lot of resistance downstream of it somewhere. The more electricity that transfers from the button to the rotor, the faster it will wear down. Too large a plug gap ? High resistance or break in wires ? Engine tune way off where major elec power is needed to spark ? Defective plugs ?

Anybody remember adding MSD's with the Old GM HEi distributor ? Those buttons would wear down extremely fast. MSD then came out with a better replacement button that pretty much cured it.

MSD Rust Problem Results in Starter Damage
 

MSD + Marine use = Junk and it breaks parts
Engines (yes two) started kicking back like timing too far advanced. Broke two starters before timing light establishes no advance cure, just total advance. I call MSD technical support and they tell me it can not happen as a loss of springs would result in retard (I think the person on the help line was retarded).
Attached is a photograph of the one remaining spring.
If you use an MSD, inspect under the cap and rotor for rust frequently. My $.02.

the carbon ball wearing is pretty common, I see it alot....

As was already suggested, I also bend the metal tab slightly so it makes better contact....

Just found the same thing with the worn carbon in the cap. I don't know what caused it but there was a lot of corrosion on the contact points inside the cap. I also discovered a bad coil, oil was leaking out. I don't know whether it was the coil, the corrosion or something else. I checked the coil on the other motor and sure enough it was leaking some oil as well.

I have been using the Accel Coil with the MSD 6AL box for years. Not that I get much run time out of my motor, but I have had a problem with the setup. It will corrode, inside the dist. I have it locked out any way, so advance isnt an issue. Using the EFI ECU to control spark advance and using a crank trigger, that made a big difference in my tach signal to the ECU.. I also use a filter cap on the 12v input to the 6AL box...
Dick