Hotrod Linc......I understand the concern with the Battery Disconnect. However, the "Fail to Start when Engine Warm" issue started long before the disconnect switch was put on the battery.......at least 2 years before. I had another gremlin issue over the past 6 months:
One day I suddenly heard someone blowing a car horn. I went outside and found my 69C10's horn just blowing away. So, I raised the hood and pulled the wire off the horn. It had a super sensitive horn contact at the steering wheel, but it was freaky to just have the horn start blowing after sitting for a few days. Then I found a voltage drain, even with the horn wire off the horn, so I assumed the steering wheel contact was still touching, causing a drain, and was removing the battery cable to stop the drain. (When I removed the battery cable, I could hear a relay turning off up under the dash.....and that turned out to be the horn relay turning off when the battery juice was taken away. I then slapped on the disconnect switch to make life simplier. Sometime after, I pulled off the steering wheel to investigate the problem, but could not find any issues. Put it all back together, and now the horn seems to work fine, and the horn relay is not clicking on/off when I turn the battery disconnect switch off.
Removing the battery disconnect switch will not solve the "Warm/No start" issue....but I do understand the fact that I am perhaps losing amps at the switch, and corrosion will be an issue over time. The truck sits for weeks w/o starting, and I prefer not to have a dead battery when I want to run her......and am not yet 100% certain that I have eliminated all voltage drains (I found the old Kraco radio was draining juice, even with the power off, so I yanked those wires from the fuse box).
So, I will do more investigating when the rains stop, and get back with more info.
That was a good thought about the headers making the starter too hot.....I will check into that, and get a picture of how close it is to the pipes. However, for over 25 years, the old starter worked fine, hot or cold engine, and I made some long road trips and had no "fail to crank" issues.
