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Well, you certainly seem to know quite a bit about these switches.
But what you don't know is that when holding the ign sw over to the start position while looking for a sweet spot on the NSS transfers all the current DRAW onto the NSS, where you don't want it. They want the NSS contact to be CLOSED and in full contact BEFORE the current draw of the starter circuit is initiaited. That way, it is the robost contactor bus bar of the ign switch that takes the spike and amp draw of the starter circuit.... not the contacts of the NSS...ever do any welding???? A good wat to kill a NSS.

I leave you there . as there is an answer to justify everthing wrong.
My preference is to do it corrctly from the get-go and to pass that info along in my diagnostic postings.
To assume/state a mal-adjusted NSS, be it new or old, will not give you trouble is foolish info to be passing on.

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A Dalton