Trouble shooting help - '46 Deluxe

[Ggmac]

Have you replaced or rebuilt your ignition switch? Does it feelloose when moving the lever ? It could be worn to the extent that when switched to the on position it doesn’t have the tension to give good contact , but when switching to the on position you’re actually putting a little pressure on the contacts , thereby giving it just enough contact for good continuity? Just a wild guess without my coffee…..
Good luck , Gary