Well so much for 3rd times a charm. After I attached the coolant lines and pumped water into the cooling jacket the plasma just stops. That tells me it is transferring through the water, the other give away was water on the rear mirror. Damn…
So I decided on a solution which will work guaranteed, maybe I shouldn’t use that word… should work. I removed the end caps put them back on the lathe and placed an o-ring on the inner diameter against the discharge tube. I will make a separate water insulator totally isolated from the end caps and use o-rings to seal it against the discharge tube. This way there is no connection between the water and end caps other than a piece of glass.
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