My truck currently has burnt out glow plugs. The set of 8 which is in the truck are bad, all the way around. I may not be able to change 1 or 2 of the plugs, I don't know yet but it doesn't look accessible( https://www.ford-trucks.com/forums/1...l#post10051774 ) so I was thinking about setting up a pushbutton system, here's what I was thinking....
A fused and covered toggle switch -inline with a push button switch connected to a relay - to the plugs which I can replace.

1) If I'm going this route, could I use the spade connecter plugs (earlier glowplug system 89-91?) - or do I need to stick to the bullet connector type?

2) What size relay do I need, or is there a way to use the exisiting relay, essentially transforming it to manual control?

3) What gauge wiring should I use to connect the relay to the plugs?

4) How will I have to adapt glow time to 6 or 7 plugs? Presumably shorter because of less overall resistance leading to faster time to overheat, anyone know how to calculate how exactly how much?

5) Will this be adequate (read better than nothing) to start my truck.

I've been without a truck basically all winter, and haven't started it since January when the plugs finally gave up the ghost. I think its only had a few working plugs at any point since I've owned it cuz the controller would always cycle real fast for like 5-7 seconds and i'd have to cycle them 2-10 times (depending on temp) to get er started. I don't believe in ether, but for all summer and fall it would start within reason given a couple of glowcylces and a 5 second crank and glow or two. I don't run er much but with fishing season coming this is a priority.

PS - I'm gonna use motorcraft ZD9s

 

the controller cycled fast because you have some burned out plugs. I'm going to bet when you replace all 8 the controller will work again. Why can you only get at 8? if you get a set of 8 ZD9 beru plugs it will be worth thee time and effort to put them in.