Melting starter wires

[John Milner]

What would cause the starter wires on a 68 charger to get hot and start to melt? The starter is new, relay is new, starter wires are new, engine wiring harness is new. I started my car for the first time the other day after restoring it and it worked fine. I'm at a loss.

[c00nhunterjoe]

The main battery wire melted? Was this while cranking? If so how long were you cranking. Verify good grounds regardless.

[b5blue]

Check connections and crimps, I had loose crimp at battery.

[John Milner]

The main battery wire melted? Was this while cranking? If so how long were you cranking. Verify good grounds regardless.

Yes it was the main battery wire. It started smoking pretty good and melted some of the red insulation off. I cranked it maybe 10 seconds? It worked great the other evening. I'll double check grounds.

[c00nhunterjoe]

High amp draw. Low battery, bad starter, or bad ground.

[krops cars]

You can always add extra grounds. I always do. Helps everything.

[John_Kunkel]

Low battery, bad starter, or bad ground.

Make sure the battery negative cable attach point has a good clean contact with the block.

[krops cars]

That is a very good point.

[XH29N0G]

For what it is worth, a new set of battery cables was installed when my car was restored.  The plastic melted and wore off because the wired heated up.  They were flexible cables, but too small of a gauge to transmit the current without heating up.  I replaced them with a larger diameter (lower gauge wire) and the problem went away.  This may not be your problem, but I would look into the gauge of the cables from the battery.  If I see the thread, I will post the link.

 

[gtx6970]

starter dragging or to small a main bat cable IMO

[John Milner]

I am going to just blame it on a bad battery cable.  I installed another one and another starter relay and I'm back in business.  The starter relay was broken.  I opened it up and one of the contacts inside had dislodged.  I ended up re-using my 1968 original Mopar relay.  I'm having less faith in "new" parts as each day goes by.

[XH29N0G]

In my case, there were several options, and the one that was chosen was the least expensive.  The problem never reoccurred after I replaced with a new, but heavier duty battery cable which was more expensive.  Good luck with your fix