Well darn. Im honestly still stumped, I agree to there being a fault in the wiring and im just gonna have to spend a good day tracing it

 

truckguy, what engine do you have? are you running headers. Seems like the starters work when new, then once you use them they fail. If you are heating them up too much the windings in the motor can become damaged. Then you draw a much higher load on the starter and smoke the cables. My 94 Bronco has a ceramic shield that acts as l heat shield. Don't know if you could rig up a heat shield?

 

Im running a 390, 184 tooth flexplate, and yes im using headers, you explained all my symptoms, like i put in a new starter start motor up let run for lets say 10 seconds, turn off, Try to start it again get a couple cranks then stopsand won't spin. replace starter works again once then repeat again,

 

Heat shield is definalty in the budget here

 

Solenoid, maybe as well?

 

If you're talking about firing up the engine from a cold start, 10 seconds won't be enough to cause heat-soak into the starter. The engine would have to be up to operating temperature and have been running for a while to cause heat-soak on the starter.

Still sounds like there are cabling/component resistance issues.

 

Got heatsheild and new battery cables the ones with the crimped ends. New solenoid, exhanged for another starter. Also got a new starter wire and a large gauge ground wire for the starter to block ground. Also i need to mention this to y'all, it concerns me alot. The starter wire post is like maybe a centimeter away from a header tube, would that also maybe be to close?

 

Well my phone aint going to let me post any pictures, ill have to get on a computer tommarow