I installed a new optispark this time last year, and also a MSD Blaster coil and 6A box. My water pump went out and I decided to fix my timing chain cover oil leak at the same time, and notice the basically new optispark rattled when I removed it. First thoughts were that my rotor melted, or something similar. Opened up the cover, and sure enough, the rotor had melted where it contacts the cap. The rotor at this spot isn't even brass or copper, it's a shiny silver color. Whatever metal it is, I guess it has too much resistance to handle the 48,000 volts from the Blaster coil and heats up. Does this sound right? If so, why don't they make the entire rotor and the contacts in the cap out of brass or copper?
Does anyone make a replacement cap/rotor that will handle this output, or am I going to have to put my old coil back on so that I don't have to fix this every 10,000 miles? Have any of you had problems similar to this? Thanks for any information you guys can provide. I need to fix this soon because I'm making a 850 mile trip thursday to home in Nebraska.

 

Maybe it is something else. I have run a Blaster coil and MSD6A on mine for 10,000 miles and recently looked inside when I was doing a cam swap. The rotor was perfect.