Quoted from PBMAN:
Thanks to Mad Dog. Problem solved. Switch gap needs to be 1 mm or less. Hitting 8 out of 10.
Reality_Studio I would ask Stern for a new switch. Once you start playing with those metal flaps they are never the same.
That's likely what I'll do, Stern has already offered to send me a new switch. Waiting to see what they suggest for the ramp first though before I have them send that out.