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)

[AZBanks]

I would suggest giving Mark Henry's fix a try.

http://www.914world.com/bbs2/index.php?sho...amp;mode=linear

[porschetub]

I would suggest giving Mark Henry's fix a try.

http://www.914world.com/bbs2/index.php?sho...amp;mode=linear

Starter solenoids are super basic,a wound coil that gets power from the key on start and repels a steel piston forward that moves an arm to move the bendix to engagement of the pinion gear to flywheel.
Starting function off on the key with engine running the piston returns back due to no coil power due to it being spring loaded .
I used to rebuild Bosch starters and very rarely found bad solenoid,most just needed a clean cause they were gummed up with old grease.
Best to take your starter to a Bosch shop and get it done right,I have a strong mistrust of "so called" rebuilt units....paint looks nice on them (IMG:style_emoticons/default/av-943.gif) (IMG:style_emoticons/default/av-943.gif) .
Other things have been already mentioned, (IMG:style_emoticons/default/beer.gif) .

[Superhawk996]

I would suggest giving Mark Henry's fix a try.

http://www.914world.com/bbs2/index.php?sho...amp;mode=linear

Starter solenoids are super basic,a wound coil that gets power from the key on start and repels a steel piston forward that moves an arm to move the bendix to engagement of the pinion gear to flywheel.
Starting function off on the key with engine running the piston returns back due to no coil power due to it being spring loaded .
I used to rebuild Bosch starters and very rarely found bad solenoid,most just needed a clean cause they were gummed up with old grease.
Best to take your starter to a Bosch shop and get it done right,I have a strong mistrust of "so called" rebuilt units....paint looks nice on them (IMG:style_emoticons/default/av-943.gif) (IMG:style_emoticons/default/av-943.gif) .
Other things have been already mentioned, (IMG:style_emoticons/default/beer.gif) .

(IMG:style_emoticons/default/agree.gif)

However, you do need sufficent voltage and current to induce the magnetic field and get that solenoid to pull in.

I'm almost wondering if your ignition (yellow line from ignition switch) is so high resistance that it has been not getting a good clean pull in of the solenoid. Over time, maybe this is causing arching between the solenoid terminals and the pull in connection bar & eroding and resulting in high resistance there as you suggest. This would be plausible if you're jumpering from B+ of the solenoid to the starter motor winding terminal works every time but the your bypass switch from B+ to the solenoid control will not.

Hard to believe this has happend three times in two years though!