A quick update..

I put the old coil back and set the air gap using my trusty business card method and you guessed it, the engine fired up straight away without the kill switch wire connected. Luckily I had turned off the fuel tap so it stopped pretty quick..

Then I connected the kill switch wire and again, it fired up without issue.

Can anyone help me understand what the hell is going on here?

Where I take the mower is a 3 - 4 hour drive from home each way and I have to mow 1500 square meters of shortish grass. With plenty of breaks of course so I'm not overworking the mower at all.

If it still cuts out without spark while I down there, I just might burn it on the spot. lol