I built a truck for my 16 year old daughter and my Ignition wire gets hot while driving and then it doesn't start unless I jump the wires at the starter. Thoughts please!
We talking about the wire going to the coil from the ignition switch? If so, then it may be a resistor wire to cut down voltage kinda like a ballast resistor. If we talking about the coil wire from the coil to the distributor then you really have me scratching my head.
Circuit is too small to handle the load, poor ground or connection, or if points style ignition and this is the feed, no resistor as mentioned. I'd also check the charging system output. Since you have the time in here and the skills, first place I'd check is the ignition switch itself. I'm sure you will be back to report your findings. This is the basic layout, but shows the Ford relay. Ignore that.
I'll try to be more specific. I only took a quick look today and it seemed like the Alternator wire was getting hot but it could also be the coil wire as well. It has a one wire alternator and an HEI distributer on a SBC. No resistor wire or ballast anywhere in the system.
What size ga of wire on "Stud " Of alternator down to starter stud or bat cable " Hot" .? Should be @ least a #10 ga with 100 amp Alt , When charging what the volts showing 13.7 -14.2 v . Bigger amp Alts can be #8 ga some times #6 ga Key in dash or on column , What size #ga wire powering the Coil on HEI ,? What size ga Ground & Hot to battery, & how far battery from starter?
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