Well sounds like they pointed you at similar things to what I mentioned. I will say that there does seem to be a few more issues with DA ignitions than maybe some other makes but DA usually makes it good if that turns out to be the issue, it's just pin pointing the thing that can be difficult. As far as heat not really affecting them, well all electronics can have issues and if it had been behind the muffler causing it to quit for some time before you moved it, it may have started the process?

On the PowerPoles, even DA suggested to me that I replace them so I changed 'em out on my 120 and the 60, but that is not an "official" position from DA... lol

I'm not sure changing out to Deans would solve the problem as it seems to be a case of the extra weight of the connectors and model vibration. It starts breaking the wires inside the insulation so it's difficult to detect and I'm thinking a Deans would be a similar issue? I just use HD servo connectors to feed the power to my gasser ignition modules just like most of the manufacturers use. Not sure why DA has those PowerPoles but was led to believe that it has something to do with the Austrailian module supplier not wishing to modify the unit.

Yeah my little aerobat that I had the issue with has a fiber optic kill switch, all my gassers do but if you just go directly from the battery to the module you bypass both components and my problem was with the off/on switch not the kill switch.