[JBanna]

A disaster just sidelined my ’78 7 miles after I solved the steering wheel and gear issue; now I’m forced to ask for help from you electrical forensic experts, and I’ll be thorough:

Last summer I had issues with my courtesy lamps and clock, which are on the same fuse, because one of my wires was pinched between the steering wheel and its mounting bracket, shorting out the fuse; eventually I found the problem and fixed it, along with installing my new quartz movement clock…all was well for several months, until I finally decided to start the steering gear project. After completing that job, I went for a drive:

First I had to charge the battery because it had been in use off and on for a couple of weeks, and the car wouldn’t start; however, after charging the battery I was able to start the car and test drive my alignment…all was right then except for a little off-center turn signal cam, meaning steering adjustments still need to be made; however, after 7 miles with no issues, I parked in a clinic and came out a few minutes later to a struggling starter, and then began to notice burnt plastic smoke coming from my vents. I turned the ignition off, and removed the access panel for that spot – to my dismay, fire was already trying to burn up my car! Fortunately I was able to blow out the fire before it really messed up the car, but unfortunately many wires are either burnt or melted – has anyone experienced such a problem? I’ve posted pics and did some general research – it seems problem wire was the brown and white resistance wire to the ignition switch, but why did it just now fail so badly? I’ve seen suggestions that the alternator could have done it, but it’s less than a year old and seemed to be working perfectly, although I did just notice the alternator post is loose and wiggles a bit; I also replaced the starter 3 months ago to address intermittent slow cranking, but the new starter wasn’t much better, so I upgraded the battery cables to 2 gauge, which didn’t help either. The wires on the engine compartment side appear undamaged.

So, 1) Is the burnt wire the ignition switch resistor, and if so can a replacement be sourced; 2) If I have to make one myself, what are the resistor specs (the length of the wire and the coil should be a certain ohm rating); 3) The wire is stainless steel and can’t be soldered, so how does one efficiently connect a new wire to the connectors at each end; 4) Causation – alternator vs starter…I’m virtually certain no wires were damaged before the problem occurred as I checked them all last summer when I resolved my courtesy lamp circuit short; 5) Whether or not the starter caused the problem, any recommendations on a quality mini starter for a Pontiac 455 with headers; 6) and finally, how much of the wiring must be reinstalled to get my windows down?

I have so much experience with this car, but new mysteries keep happening…thanks for any help!