Well, the brain box bench test results are in from LSE, and the intermittant failure mode can be replicated on the bench...intermittantly.
Seems that at first power-up on the bench, the timing indication goes from it's normal 37 deg BTDC to TDC...not good.
After a little warm up time on the bench, the problem goes away, and stays away (similar to what I saw when it was on the plane). Alternatively, the failure mode can be corrected by simply pressing on the brain box itself. Yikes.
Therefore, it may be a cracked circuit board, but that's not conclusive. Since LSE went to newer technology in 2001, the parts to repair this are not available, so it's back to the drawing board for a fix.
Prudence and safety dictate a scratch for OSH this year

and a methodical, thorough repair. No need to rush and compromise any aspect of this fix in my book.
I'm exploring all options, and the top options to surface currently appear to be:
1. Upgrade the brain box to Plasma III, and upgrade the crank sensor to the new style product (required pairing of equipment to make it work). Since I've already invested in new coils, cables, plug leads and plugs, this may be the most cost effective (quote is enroute).
2. Switch to an ElectroAir EI. Would require a new system, but installation, especially of the timing sensor seems simpler (to me at this point).
3. Go to Slick or TCM mags. May sacrifice some performance (fuel flow and temps) in mid-high altitude cruise, as well as high power performance. Both are factors, as I'm at a 5,000 MSL airport, do cruise up high at times, and would like to do some SARL racing. Of course, the pro is mags are serviceable/replaceable just about anywhere...simplicity can be good too!
Doing lots of research at this point, including discussions with Mahlon at Mattituck and Mike at ElectroAir to supplement my discussions with LSE. Going to post a separate thread to see if I can get feedback from users of both EI systems.
Not the news I was hoping for, but just gotta suck it up and do this right.
Cheers,
Bob