Latest update.............
Checked the battery on a load test.........OK
Had auto parts store check alternator on their equipment............OK
Re-tapped lug for slightly smaller nut............good and tight now!
After 3+ hours under the dash and engine bay, I have disconnected as many circuits as I can find and all fuses one by one with no change. I show a drain on the amp meter of 1.3a, even disconnected the voltage regulator.
I'm pretty stumped at this point. I looked around under the engine and saw that the headers run VERY close to the starter. I have a heat shield installed for the connections to the solenoid but could the heat be affecting anything inside the starter motor itself????
See attached pic.
Anyone have any ideas??