I see two likely possibilities here (at least...maybe more) and you may have to eliminate both to see if they are the problem.
 
1. This sounds like the classic starter dragging when hot problem that is very common on Chevy's. How close do your headers come to the starter? You may want to put in some sort of heat shield to test to see if that is it. I believe you can buy shields for your starter at most local parts stores or online. If you can find a way to shield your starter on a temporary basis with a piece of metal in between your starter and headers where it won't fall out, you can try that to see if it helps.
 
2. You may be getting a voltage drop between your battery and starter due to a bad connection at the battery terminal, the battery cable being too thin, or a poor connection at the starter. Clean all connections well with a brass brush and make sure they are good and tight connections. You can also put a voltmeter lead at the starter before and during cranking to see what the voltage level reads there when cold vs. hot.
 
If one of these two don't turn out to be the problem, you may have got a bad starter even though it's "newly rebuilt"..it wouldn't be the first time that a bad part came over the counter.
 
The wire getting hot at the coil is because you left the key on to provide a path for current to flow. This is not a good thing on a car with points ....as it puts pits in the points fast. I'd check the points ASAP for pits, file them or replace them and check the dwell. Also, fix any frayed wires.
 
One last thing ....when you say "NOTHING" happens ....you mean the starter is not turning the engine over .....or the engine is being turned over by the starter but it doesn't start? 
 
                                                         Steve
 
-----Original Message-----
From: [EMAIL PROTECTED] [mailto:[EMAIL PROTECTED]On Behalf Of [EMAIL PROTECTED]
Sent: Friday, March 14, 2003 1:42 PM
To: [EMAIL PROTECTED]
Subject: [Chevelle-List] Starting Problem ??

I have a qestion regading starting my car. When I start the car I have to use a battery charger, but however I took the battery and had ur tested and it reads well and its not in the battery. When you turn the key it wont start but when you put the charger to it it starts and runs, but then when you turn it off NOTHING !! Then you sit for a few minutes and it cranks again. And the process repeats itself over and over. I have put in new plugs, starter, coil, wires,distributor, points,cables, coil and so on as the list grows. There is only one thing that I have noticed is that the ignition wire coming from the harness to the coil is frayed and gets hot when you leave the key on. But the engine still starts. I have a 350 cu in in there.  Any suggestions or solutions ?? Playing process and elimination is taking its toll on me and my wallet.....thanks for any help someone can give

John
Malibuman66
Phila, Pa

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