Starter Solenoid, I have been through 4 and counting! Options

[ctc911ctc]

1974 2.0 - 24Kmiles
All stock

I received the car in late 2018, pulled from a garage in RI. Sat in the garage since 1986/88

The starter in the car was original. We removed near everything in the car, super cleaned and welded, put it all back together, and also bought a new starter. The new starter would not work right - clicked but no turn - so we put the original back in. Ran great.

Then the original started to fail (seemed like the copper wire from solenoid to motor had degenerated so we bought a 3rd. This one would not work so I returned it and got another. It worked great for a month and now this one clicks but the motor does not turn. Had to jump it with a screwdriver. Which though dangerous - works great!

At this point, over 2 years, I have 4 failed starters. One is 46 years old, the others are rebuilt (2) and new 1.

Which way would you go from here?

Another new OEM? (IMG:style_emoticons/default/blink.gif)
Another rebuilt???? (IMG:style_emoticons/default/barf.gif)
Put a relay in parallel with the Solenoid? (IMG:style_emoticons/default/smash.gif)
Get the super fancy Porche High Torque starter? (IMG:style_emoticons/default/first.gif)
Always park on a hill (facing downhill of course). (IMG:style_emoticons/default/lol-2.gif)

[fixer34]

Now that we beat the electrical issues to death, what about mechanical interference? As mentioned, it seems there is a good clunk when the solenoid engages, but the starter never turns. The pinion drive has to extend all the way for the crossbar to make contact and spin the motor. Is it possible there is something inside the housing or on the flywheel that is jamming the pinion? Should be able to pull the starter and look inside while someone turns the engine over by hand.