Al sent me some pictures for this thread.
A breaker removed from the panel, it does not look to bad. If it was still in the panel with conductors in the terminals we would not even notice one lug is a little dark.
A Flir Image of the breaker when it was operating.
A little closer look at the terminals.
Still not looking to bad.
Now we are getting somewhere, this is not good.
I got to see in person the busbars Al removed from this area of the breaker, they where quite warped due to the extreme heat they had been subject to.