I cant say for sure not being there, but I have seen many of the big copper starter post (where switch engages) worn down too low or carbon or pitted to the point even a good switch fails to make good contact. Of course as you're already aware the switch has to push down hard and far and deep enough to make good contact.
In any related cases I advise people to remove, clean n wire brush and re attach each and every battery and starter and ground cables and a ground to any thin wimpy rusty sheet metal part can cause a starting problem, I like a ground cable ran down to heavy solid clean shiny metal near the starter.. Make sure the battery is full charged and in good shape also. A loose or burned or corroded resistive connection anywhere in the circuit can cause excess line voltage drop causing poor starter performance.
HOWEVER if as you describe it cranks okay if jumped direct to the starters big side copper post/stud but NOT otherwise sounds more like a switch failure (not deep enough hard solid contact) or the starter post has a problem and they can be replaced if worn too low or damaged...I have cleaned and smoothed them down making them work again.
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