1. In 38 years as a service tech, I have never seen a Ignition wire burn/melt off
2. To have 2 do it, points to you having a severe Insect infestation. NOT a defective Furnace
3. The soot is caused by burning LP without enough air. The furnace is designed to have the correct air/LP mixture and there is NO adjustment
4. You problem as I stated is the Interior chamber is clogged with Insect mud nests and insects. You need to disassemble the furnace and clean it out. I disassemble and run water thru the chamber and you will be amazed at what comes out that you cannot see. You must do this and then reassemble and run the burner to evaporate any moisture left in the chamber. Doug