John, we don't say it's your hardware, it's a combination of hard and software.
The hardware is a little critical and the software will do the rest.
Thats why I want to redesigne with the MC34063 a new hardwareboard.
It have the options to stop the HV if there is no spark needed.
It also controles the HV-Voltage and there are no components who can overheated.

We can try, if it is not a good designe we stop to find a other good HV-board.

You have also mention, I need the CDI for my bike so I need a secure CDI.
You can make your plane (..) plug and play, but I need more then 1 hour to replace the CDI if it fails.
Beside the road, into the rain or snow I don't think I can handle this......I think I leave the bike.