Welcome back to Ogauge, Bobby O. All good points. Interesting point on the switches. I have 12 of them on the mainline of my layout and only one has ever had a problem. The only one that has burnt out, which I have also never replaced due to it being embedded in my scenery (Its in the front so I just turn it manually) is the one that was powered via track power. All of the others, which have never given me any problems, are all connected to a separate transformer located under my layout that is attached to all switches with a low amp circuit breaker. I wonder if that helped preserve my switches from the defect you mention. The other thing I've done is remove the black topping with a scotch brite pad on the switches and all real trax. I found this increases continuity and DCS signal strength as well as lowering the sparking. You may want to try that as well.
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