NO Start with chip installed

[sandfantom]

Installed my Phoenix chip yesterday. Followed the instructions on the cleaning part and install. Went to start and just cranked over. Did get "wait to start" light. Removed chip......started fine.......cleaned some more. Installed chip.......no start. Removed chip....cleaned some more....almost to the copper now. Installed chip but did not screw down case this time.......started. Sounded great. Tried to screw down case and truck died. Moved case around and truck started. Moved case again truck died. Got it started again and wiggled the 6 position switch wire and truck stayed running. Went for a test drive on 80 dd and WOW. Drove about 4 miles and truck died going down the road. Could not start the truck, just cranked. Had tools so pulled out the chip(in the rain). Got everything plugged back in without the chip and started and ran fine. Drove about 40 miles with no problems.

I am sure this is a connection problem but WTF. If this thing is this finicky I am not sure I want this in my truck. With the chip in the PCM and in the case, the fit is really tight and I have to work at screwing the case down. Do I need to cut out the back side of the case where the chip is?? I used duct tape to secure the chip. Also, the last time I cleaned the J3 connector I slid the chip back and forth on the connector to kindof wear in the connections.....I don't know how much more I can clean this thing. Copper is already starting to show.

Any suggestions would be great.

Thanks