Ignition switch failures.

[toolboxchev]

Originally Posted by HO455

I am wondering if anyone else has had more than one ignition switch fail? I lost one in August of 2018 and one just yesterday. The truck has been driven just over 25k miles between the failures. Both switches failed at the solenoid connection tab. The SOL tab and the ACC tab become shorted together.
The truck has had a new under dash harness installed prior to the first failure. The charging system has been converted from the stock system to a CS130 system and the starter has been converted to a late model GM gear drive starter after the first switch failed. It has been more than a year since both of those modifications were completed.
Photos of both failed units. 1st and 2nd pictures are of the first failure. Third photo is from yesterday's failure.
Thanks in advance for any input.

I have had that happen many times over the past 15 years until I figured out the main culprit.

The heater fan. Turns on when keyed to ACC ON position. Are we correct so far?