A Well Worn Cap
Back in the Old Days, the Ignition Cap & Rotor was replaced about every year with an annual Tune Up. The reason is that a Cap & Rotor is a wearing part. With accumulated engine hours, the inside of the cap can become coated from dynamics within the electrical environment, temperature changes, humidity and contamination. The result is eventual carbon tracking (an unwanted electrical path) that leads to misfires or loss of power. Additionally, the metal contacts in both the cap and rotor become worn down, bit by bit, with the transmission of electrical current. As the contacts become worn, the gap between the rotor contact and the cap contact becomes larger. This requires more voltage to make the jump, putting a strain on other ignition components, such as the points, condenser, and coil. This is the reason for the annual Tune Up. The Cap & Rotor are relatively cheap and easy to replace and will insure that you are not decreasing the lifespan of other components.
Materials that the the Original Manufacturers chose are also important. The materials originally specified were chosen to be compatible with the complete electrical system of an engine. When aftermarket manufactures use different materials, strange things can happen. Different plastics, for instance, have different properties, such as Dielectric Strength and the Comparative Tracking Index. Over the years, overseas aftermarket products have moved to cheaper plastics to save money, but that may not save you money in the longer term. Additionally, the contact material is often changed from the original. Where brass contacts for the rotor blade and distributor cap terminals were once used, aluminum may now be an alternative to make the part cheaper.
Rotor shown upside down to illustrate gap
Lastly, the construction and assembly of the cap & rotor are important. For best results a cap & rotor should be purchased together from the same manufacturer. This ensures that that the clearance specifications are working as intended.
For instance, the contact gap between the cap and rotor illustrated here should be within OEM specification. However, this may very greatly if a rotor comes from one manufacturer and the cap from another. If possible, try and order a cap & rotor as a set or from the same manufacturer.
For instance, the contact gap between the cap and rotor illustrated here should be within OEM specification. However, this may very greatly if a rotor comes from one manufacturer and the cap from another. If possible, try and order a cap & rotor as a set or from the same manufacturer.
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