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Out of curiosity last spring I spent a few days reading all of the optispark posts in my spare time. Whew!! I got the impression that the biggest problem is the original gasket or sealer between the cap and the base, and that sealing the two parts together properly minimizes trouble. True? I know the early versions had problems with venting, but I have the impression that it is not the primary problem.
One more thought...The high voltage arcing at the terminals from the rotor creates ozone. The ozone is a highly oxidizing gas that will destroy most of the parts inside the opti. That's why cross venting is valuble. - keeps it dry and removes the ozone.
This is one of those gases that is generated from regular old oxygen - O2 in the presence of a high energy source turns it into O3. Lightning, arc welding are the most common sources...