Problems with an aluminum Vortec distributor

[speedygonzales]

Summary for those that don't want to read: Was going through distributor caps and rotors so fast, I had to bring spares on long trips. No joke, I had to replace them on a return trip from Jersey to Virginia at a state rest stop. I think this will correct that problem.

I think the inside corrosion was creating an environment that for lack of a better term, "bred" more corrosion.

So you know the drill, the OEM plastic distributor cracks at the cap mounting holes.
You decide to replace it with a nice aluminum aftermarket unit like the one from Summit.
https://www.summitracing.com/parts/sum-850098

All is good and life goes on. For a few years. Then you start eating caps and rotors like Hitler through Poland. I mean real bad. Here's a picture of the cap I took off yesterday with less than 400 miles on it. Incidentally for more than 10 years, I never had this issue with the OEM plastic POS.

https://s1371.photobucket.com/user/S...sfnzx.jpg.html
NOTE: Seems that no one offers caps with brass contacts any more.

Here's the inside with cap and rotor gone.

https://s1371.photobucket.com/user/S...spgic.jpg.html

Here is what I think is causing the issues. The corrosion on the top surface inside the cap.

https://s1371.photobucket.com/user/S...8y6oh.jpg.html

I removed the optical pickup and cleaned the inside surface and painted it. Then baked it on. My hope was to seal out the corrosion and prevent premature wear to the cap in the future. Time will tell if it works.

Incidentally, the 2 vents in the bottom, which for some reason were made to turn right angles were clogged solid with corrosion as well. I drilled straight down so the holes were straight and cleaned out the ones at a right angle so it will breath better.

My suggestion for those that live in a humid environment and buy one of these aluminum distributors, pull it apart and paint it before you install it.