High volts
overall loss from batt (+) to VR = ~1.1V key on, engine off............................
loss from batt (+) to firewall side of bulkhead connector ign wire = ~ 0.45V.
Don't understand. The firewall has TWO sides, the engine side and the interior. Which side? If you are talking about the ENGINE side, then the bulkhead connector itself is probably to blame
QUOTE=txstang84;1969879600]loss from ign wire bulkhead connector to ballast resistor = > 0.5V (this concerned me-nearly half a volt just in a couple feet worth of wiring!).[/QUOTE]
I assume? guessing? you are measuring from the engine side of the firewall to the ballast? Assuming your meter is making good connections, it is the CRIMP connections themselves, and that right there is half your problem, no pun, 1/2 a volt!!!!!!
QUOTE=txstang84;1969879600]I also measured loss from the inside of the cabin from the connector to the ignition switch harness[/QUOTE]
I do not understand from your description what you are measuring here. I'm guessing? the interior side of the bulkhead connector to the connector at the ignition switch?
Which wire? ignition run? which SIDE of the ignition switch connector? under-dash harness side? ignition switch side?
If the last is true, that seems OK.
One way to do this is "rig" a long clip lead to the battery hot terminal, and LEAVE it there. "Big stud" on the starter relay is OK.
Now work along the "chain" and be specific, some of these parts of the "chain" are easier to get to than others
The following might be example readings, key on, engine off
Starter relay stud---zero volts
Fuse link at engine side bulkhead connector (unless modified): zero
Fuse link wire at interior side of bulkhead (unless modified): .05 ?? volts
ammeter terminals (unless modified): .07 V
Ignition switch connector, battery feed, switch side: .085v
Ignition run wire out of ignition switch, switch connector, dash harness side: .098v
Ignition run wire on engine side of bulkhead connector, .1v
Ballast resistor at ignition run wire, .15v
Notice each connector adds a small amount to the mix.
If I understood your last posting, you lost nearly a half volt from the engine side of the bulkhead, in the ignition run wire, to the ballast resistor. The "only thing there" is a crimp connector on each end of the wire!!!!.
