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Tim,
I should have looked closer instead of looking and fiddling with everything else, so you were right.
It had cracked right through one side of the 2 lug flange on the blind side so you could not see it until taken right out of car. As soon as the key was turned to on, it was forcing the lugs to hinge down and thus causing the loss of contact when under circuit use.
So with what you and Gordon have said, I shall have greater awareness in future.
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