Thanks, guys.
I really appreciate your feedback.
I have the Blaster 2 coil mounted up on the intake manifold in front of the distributor. It is in a coil mount and is mostly vertical, kind of like the "Leaning Tower of Pisa". I don't think my issue is the coil, as all I have to do is ICE my MSD 6AL (or put a bag of ICE on it and leave it there) and all the problems go away.
All connections have been triple checked - the proper AWG wiring is used, and the proper voltage is present (at input). My Alternator is a PowerMaster 140amp single wire.
I've called MSD Tech. support, and have an RMA # for the 6AL. I'll be sending it in some time next week. MSD said they would bench test the unit, under load and hot, and see what might be going wrong with it. The MSD technician I spoke with (Joe) said that it could be outputting too much voltage, and may need adjusted. He said too much voltage could cause the unit to overheat. This would be a problem internal to the MSD unit, so they need to test it to see.
Thanks again!
--Roger