Gazim,
Don't be confused. There is nothing wrong with your setup. You are right-on...it cranks great when cold, and that's key to this problem.
When the starter gets warm, its internal electrical resistance increases and it loses its ability to crank the engine over.
This has ABSOLUTELY nothing to do with its ability to pull the solenoid in...it does that fine, hot or cold.
All the little wires and Ford switches and the hot start thingys and all the other do-dads are only dealing with pulling the stupid solenoid in...very insignificant.
Your solenoid pulls in just fine...its the darn starter that won't spin when hot. If your solenoid DIDN'T slam closed, the starter would do nothing and your post would say "starter won't do anything".
Your engine is in fine shape..timing is great because you don't experience any kick back associated with excess advance.
You have insulated the starter from the hot exhaust to the best of your ability...it still is a marginal start when hot.
It is the starter. Like wrenchbender mentioned earlier, this application seems to require a HD starter.
That starter probably has much larger field windings...more copper, more oink!
Again, I will say that the hot start thing might work, and probably has worked. Don't know why!
If everything is as you have described it, your problem is a classic hot starter.
Stuart
