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this is a post from way back in 1994...  back when i thought i knew 
something.

> Deja Vu--
> The Dreaded Delayed Start.  I fought this worthy adversary, nearly
> lost my mind but emerged victorious.  Scenario:  Cold, morning, turn
> key and if you're lucky it starts after a perplexing (1-2-3 second)
> wait.  Maybe no start.  Get out.  Crawl under van and rap starter
> once with hammer, ahhhhhh. cranking now.  One comment, the cranking is
> getting very weak despite a new Interstate (TM) battery.
> 
> My delayed start (and weak crank) eventually turned into no start
> (unless the hammer rap, my wife got adept at delivering strategic
> blow too).  I removed the starter and 'went thru it' and thought I
> solved the problem by polishing up a somewhat sticky/corroded
> solenoid.  Replace starter expecting the world but got slapped
> with no change.  Remove starter, order new solenoid assembly and
> replace.  No change.  Remove starter, take to my favorite auto
> electric guy and have him 'rebuild' it.  Replace starter, no change.
> Add an additional big-ass welding cable to the existing one and
> clean all negative grounds.  No change.  Many desperate calls
> to rebuilder, lots of advice and vain searches in the ignition
> switch, wiring, etc.  Remove starter, take back to favorite guy and he
> 'goes thru it' again.  Everything tests fine tho he says.  Replace
> starter, no change.  BTW I'm getting VERY good and pulling this
> sucker off now.
> Check all appropriate voltage drops and fix up a few bad
> connections.  With me at my wits end my rebuilder says I've been thru
> the mill enough and that some-times a problem just can't be found
> while its on the bench.  He orders a new Bosch unit from the dealer
> and gives it to me (yes, I said gives as in free) stating he'd
> rather keep me as a customer and have me speak well of himbut he's a
> good guy with a family to feed so I pay half.  Replace with new unit
> and everything has been fine for over 2 years now.
> 
> BTW, if you live in cold climes, I highly recommend adding to your
> existing starter cable with an additional one.  I can't remember the
> guage of welding cable I added but in retaining the existing one and
> adding the monster I effectively tripled the OE diameter.  The van
> just simply cranks and starts at all temps including sub -30 F
> mornings.  A fresh battery helps too and maybe I bought a bill of
> goods with the Interstate but it sure works.
> 
> Dan Houg -- '85 Weekender

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>From fairwind@northernnet.com  Sun Dec  4 17:27:50 1994