71 cutlass 350, swapped from points to HEI. bought a remaned distributor from the rock.
New Ngks Gapped to .45
New Moroso blue max wires.
New cap, rotor, and coil.
Ground strap present in cap.

This is less than 40 miles, car didn't run too well as you might imagine.

any ideas?

 

Try closing the gap on the plugs to .035 to start. No need for that big a gap. That looks like a cheap carbon button also. The bronze colored ones will last longer. Frankly the parts look like cheap products. Hard to tell from the pics but are those aluminum contacts in the cap? Those rotor contacts are just held together with that black plastic piece which probably allowed the spring and contact to corrode between the two. Good stuff is riveted together. Upgrade to the good stuff and try again.

 

I've had problems with those HEI buttons before. Some of the aftermarket ones are just crap.

 

Also if the rotor was not against button solid, the gap will arc and the end result is the same. I'd leave the plug gap at .045.

 

Agreed. A nearly half inch gap is way, way too big.

Seriously, the button overheating is a known issue. As said, get good quality parts and all should be well. My HEI has factory GM innards and has worked well since the 80s. You can get premium cap/rotor/etc from the NAPA/Echlin line or from the Blue Streak line.

 

I knew somebody would catch that..

 

I went to Napa and got the "premium" cap, and rotor.
Funny thing is the one that fell apart was an Ac Delco from the rock. I paid the extra because I didn't want cheap crap...

 

If the Delco cap you are talking about is the one in your first photo, it doesn't even have brass terminals - it has the cheap azz aluminum ones. Much of the AC Delco replacement line is made in Mexico, India, or China now. Note this Standard Motor Products carp from RA, especially the brass terminals.

 

GAH i think i have that cap on the shelf waiting to go in my car