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)

[ctc911ctc]

*******UPDATE*******

The original Starter has a tired solenoid - took it apart and the crossbar was burnt out.

The second one I got had a cracked mounting ear ( where the long bolt is threaded through), I took it back for the 3rd one.

The third had a stuck extension gear, the solenoid was fine. (More about this later)

The fourth (bought on Amazon) had the solenoid stuck and the jumper wire from the solenoid to the starter burned through when I turned the key - had to disconnect the battery.

I then rebuilt the solenoid from the 3rd and the starter motor from the third (stuck extension system) and it works fine. The extension system needed grease. The solenoid needed the plastic spacer to be milled down to a thinner spacer so it would allow the crossbar to reliably engage. The plastic spacer, (in between the two halves of the solenoid), had burrs and other excess 'plastic-flash' that I removed.

The forth I bought on Amazon and was able to return it to the checkout counter at WholeFoods...........what an un-natural act......

Car is starting reliably, fun to drive and there are still 100 'little' projects.......sigh