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Yeah Mud, I would say starter. when you pulled the coil wire and it stil occured you took the engine itself out of the equation. Oftentimes electrical issues don't show up until things are hot. This is due to changes in inslulation dielectric strength, resistance, etc. You could have some shorting going on in the starter winding that doesn't reveal itself until you get things warmed up. This shorting in turn would tend to degrade the "strength" of the starter and hence the ability to freely turn over your powerplant. The shield will help I bet, BUT, be aware that the heating up of the starter will only have an effect when there is some insufficencies there to start out with. I would watch that starter realllll close. You could use a amp meter to check draw with the starter cold and then hot. Might she some real light on what is going on.
Just my .02
George
PS By the way, recheck ALL your connections for tightness and make sure the contact areas are CLEAN. ANYTHING loose or not making good solid contact, will cause a high resistance connection and could also lead to the issues you are having
If it is while it is being cranked it is most likely the starter overheating because of the headers. When I rebuilt my starter I took it to a shop and told them I had headers and that the starter was only 1/4" away (66F100). They said they would do something to the starter, I cant remember what they said but, I haven't had any trouble starting the truck when hot and 95 deg. outside.
I wasn't tracking whether it was lugging after you got it started or during the cranking. I'd put my money on the starter getting too hot from the headers. I just had headers put on my '69 and the starter is real close to them. I'm anxious to see how it works out.
If the engine is warmed up & i shut it down and try to restart right away....it starts normally ...if it sits for just 2 minutes...its lugging! Im thinking the starter doesnt have any air blowing past it to cool down and picks up heat from the hot headers.
I would check the fuel lines to see if they're too close to heat. My truck was vapor locking after it was driven for awhile and when I tried to start it after it was warm it would "lug". Moving the fuel lines away from heat made a difference.
The problem may be the battery cables themselves. I just replaced my Neg cable with a larger diameter and longer length, however the starter began to act up. It would not start at all some times. The sel would work but no engine turning. I read in the Hayes book, to make sure you use the same lengths and diameter. I switched it back and every thing works as it's supposed to.
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