Problem solved and thank you all for your much needed input to get my old girl back on the road where we belong! The problem was the brushes' braided bare wires were left a tad too close to the starter housing after rebuild. There are four braided and bare brush wires- two are grounded with screws, two are hot and none are insulated. Protection from grounding out (arching) is strictly the routing of the leads. The two hots are connected by an insulated piece of wire which connects them together "after" the brushes. Route the hot braideds close to the central area of the housing at the expense of the negs as they don't matter as they are bolted to the end cover anyway. Be cool, fb
ps- The brush holder pivot pins are insulated with a non-metalic cup that is pressed in with the pivot pins at the time of manufacture. -fb
Last edited by freezerburn; 06/24/2017 5:41 AM.