As a precursor, I was already frustrated with the suspension I designed on another car. Damn CAD wheel model doesn't match the rear wheel and the lower control arm is touching. Booooooo. Should be really sick when fixed...
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But I am digressing so here is what happened (Lots of bad writing/English and the word "so" ahead and I'm not responsible for you getting mad)
I took the new starter off but left the wiring in place, pushed the switch and it crawled for a sec or two but that was it. I thought maybe the battery was drained but no, it was fine according to the charger. So I took the starter completely off moved it to the battery with new connections and bam, it moved.
At that point i was more confused so i hooked up the older starter the same way and it ran as well. Now I was thinking the problem only arises when it is mounted in on the engine. With the wires disconnected, measure the the starter main wire, 12v and measured the starter switch wire (button pressed), 12v. Then I did the same test with the wires connected but not the alternator wire and guess what!!!! Nada.
So I put it back on the engine and tried it again... nada. Added two grounds... nada. I also removed one wire from the switch and touched it to the other wire on the switch and still nothing. WTF? I kicked the car a bit nada. Ate some dinner and that didn't help either.
I was lost so I took off my frustration pants and put my big boy pants on and re-tested everything again. I checked the ground and it was good. I checked the main wire, 12v probed the starter wire from the back of the terminal and 5v.
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Hubbbbaaaa whaaaaaat? (that's from "the pigeon finds a hot dog" book, its good! Go read it!)
So I pulled that wire off, crimped on a new connector checked that the voltage was 12v and placed it back on the solenoid end. I closed my eyes, all excited of course and pushed the start button and.... still not working!!! So much pain, and anger and depression running though my body at this point like you are staring down the guy who causes you to crash on the track. I pretty much lost my [PooPoo] at that point but continued once I cooled off.
I then tested the connection again while connected to the starter and it read 5v again when the button was pressed. Not cool. I decided to run a wire all the way from the front of the car to the starter eliminating the wire, switch, etc and boooommmm she started right up! Did it a second time and it started right up.
So there is something up with that wire and maybe the switch. I don't know why the voltage is changing though and that's weird. I am thinking that maybe the wire is shorting somewhere (could be the drain too!) but i need to take the floor off and look at it.
THE PLAN:
Run a new wire from the starter directly to the switch and see if it starts. If it if does not start then it is a switch issue. This should work since I was manually touching the wires together however, one wire was always left on the switch while touching it with another. From there it should be obvious.