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Use a new ignition switch, or at least, if you insist on using a used part, make sure it wasn't the subject of one of Ford's many "ignition-switch-sets-the-vehicle-afire" recalls.
And don't add any accessory load current to the ignition switch. Use relays.
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Douglas Campbell [drcampbell ot engineer dat kahm]
November 5, 2008: The fat lady sang. Back to actually working for a living.
1986 Isuzu P'up, 177,673.8 miles. Hella headlights, (highly recommended) DOT C-2 back end. (also recommended) R-12 air conditioner converted to R-406a. 4.1:1 rear axle converted to 3.4:1.
9/22/2007, age 21: Still running well when reluctantly sent away for reincarnation, due to body & frame rust.
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