I've finally got everything running well, with the Aldon Ignitor electronic kit installed. I made several changes since my first (failed) installation, so I really don't know which one made the difference. I'll list them in case anyone else has trouble getting an Ignitor kit working:
- changed original ballast coil to DLB105 (standard Lucas 3 ohm non-ballast coil), and bypassed both the pink-white ballast wire and yellow-white wire from the starter.
- opened the hole up in the Ignitor mounting plate. I used a 7mm drill bit. This was to provide a bit of adjustment to enable me to increase the air gap between the sensor and rotating sleeve. I increased the air gap to a generous 0.90-1.00mm (previously it was a fairly tight 0.70mm - probably a bit less).
- scrapped the manky looking black earth wire in the dizzy and replaced it with a new one
- renewed distributor cap and rotor. The old ones weren't that worn so it probably made no difference. (I measured the distance between opposing points on both old and new caps with callipers - there was about 1mm difference if that.)
After making all these changes, it started up effortlessly on the first attempt. The position of the static timing was the same as on my failed attempt last week (I know because I'd marked the position of the dizzy with Tippex for comparison). I did a test drive round the block and discovered that the engine knocked significantly at anything above 15mph, so I stopped and retarded the timing a little. This worked brilliantly and the car then drove well. All that was left to do was to take it on a blast down the M5 to recharge the battery, which was as flat as a pancake!
My strobe light didn't arrive in the post yesterday, so I couldn't set the timing in the proper way. I'll do that over the weekend instead. But even setting it by ear as I did yesterday, the engine appears to be running a little smoother than it did previously on its conventional ignition.
Thanks to everyone who made suggestions! I definitely feel more at ease now I've changed over to a non-ballast coil as Steve-O suggested. The whole front wiring loom looks tatty and geriatric so I didn't have much confidence in the ballast wire.
As to what caused such problems on my first attempt, or how the spark plugs got so damaged in such a short space of time, I can't be sure.
Edited by zero_wlv, 09 September 2016 - 08:23 AM.