Rob, it seems I have found the cause of the unit sparking by itself!!! As I tested it the first time the battery was fully charged fresh from the charger and voltage was 5.6 volts... after first testing was completed, about 20 minutes time had gone by. Well, as it seems, the unit is very power hungry and consumed enough voltage from the pack (4- 700mah nicads) so that the end voltage after the LP2950CZ regulator was below its dropout voltage and the unit was resetting the pic startup. As I see it now, I can't go to 5 cell pak because overvoltage does the same thing as under voltage..creates it's own sparks.

So I have found the cause... now to find the cure! Oh, by the way..I used the New Cdi to run my newly converted weedeater motor today...P E R F E C T !!! Absolutely flawless! Now if I can figure out the voltage drop problem, I'll have a perfect running system.... Everything you have changed over the last 6 months was added to this PCB and I must say, if someone followed this forum and knew how hard we all work...especially you Rob... Thanks a Million !