Thanks Dave, frustrating as heck for all trying to help and myself.
I have done some of what you and others recommended.
1. Havent checked motor to body ground strap. I will chk, but it is a newer woven one. Battery connections are good, new -ve ground cable installed.
2. Both VR and ecu have been removed, cleaned connections and grounds. Already had toothed washers installed.
3. See above
4. Ballast connectors removed, they are good and clean. I did a visual on the BH connectors and they "look" good.
5. Havent looked at wiring at starter. Will chk.
I havent looked close under the dash, out of sheer dread lol. But I also think its under the hood somewhere.
I am going to test coil +ve in run and crank. When I checked with my test light and key on compared to crank, the brightness did not change. It should get brighter(full voltage) at crank/start.
A couple things I noticed when checking wiring,
1, the brown/white ecu wire that leads to distributor connector has a small "nick" right at connector. With car running, wiggling that wire didnt do anything, but an ohms check and continuity check, it appeared to fluctuate?( car off and ecu unplugged)
I will see about replacing it.
2, fusible link at starter relay that leads to alt stud is pretty warm. It may be too small of gauge, it is 18 ga, I'm going to replace with 14 ga. See pic with hand drawn schematic, I wrote 14 ga, but it's 18. Also on same stud at starter relay is a fusible link I installed when doing Mad Bypass. It MAY be on the small side as well, its 18 ga, but on my schematic its 16 ga. I will look at replacing it as well.
Another quirk when trying to start, coil -ve wasnt flickering with test light, but when checking coil +ve, after a second or 2 of cranking it fired up??....did grounding when checking coil +ve cause it to start??
Oh, fuel gauge is fine. I have modded dash harness, Mad Bypass, Ivr mounted for dash, triple gauges.
Thanks for input/advice.
yeah this is baffling it all sounds like its hould be fine
few things i might try in your position
1) undo clean and re do the earth strap from motor to body. and if you have bollt ends to your battery wires do the same there...expunge any greenness
2) undo clean up and re do with spikey washers, the mounting of the voltage regulator
3) undo and re do the mounting for the igition module
4) clean connectors at bulkhead and both ends of ballast
5)If you car has a lead from a 3rd connector at the stater motor. make sure it is connected and has not shorted to the exhaust, this is a 12 volt feed swicthed on by the starter motor and it runs to the igntion end of the ballast. starter has its fat wire to run the motor, and its swicthed wire to switch the starter motor on by the key, some have a 3rd wire which is your 12 volt feed to the igntion when the key is in start position.
funny tach signal keep king lead away from any control wireing and keep tacho green coil lead away from as much as possible
A short in the tach lead can result in the car not starting if that lead has shorted out to something at 8-12 volts (8-12 on both sides of coil results in zero voltage across coil and no spark) i'm thinking some power feed behind dash or on back of dash cluster
crazy tach issues are not uncommon when the tach is old and its capcitors have all dried up. bad tacho after a long lay up sometimes gets better as use tends to shock the ageing (but not shorted out or broken down) capacitors into functioning again...a bit like an old 1950s radio..hums badly when fist switched on but the hum slowly decrease with use as the capacitance of the aged capacitors increases slowly back towards what it should have been as they warm up. its like somthing inside the capcitor did a bit of ironing and straightend the withered conductor and insulator sheets out again..
one other thing my car is 12 volt across the dash i have no 5 volt regulator
i know some US cars have 5 volt regulator for fuel gauge etc i don't know if this 5 volt feed is used for the tacho as well... if your regulator was busted your fuel gauge at least would be acting up... is it?
Dave