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Just to finalize this epic ordeal...
Turns out, at some point in time, my car lost a large grounding cable between the battery and the engine block. The only path for battery juice to get to the starter was through the little braided strap on the valve cover, which is woefully inadequate for carrying 250A. Solution was a 4ga. cable between the (-) post and a convenient block bolt. Car starts instantly, and I even get better running voltage now. The car ran fine when pop-starting because the alternator was well-grounded.
Thanks for all the helpful posts concerning this deceptive problem.
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Speed Racer, '83 240 R, '74 164 E, '93 940 OL1 (Manchester, CT)
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