All Small Six My Car EATS starters!

This relates to all small sixes

Rev.LowBuck

Active member
I've posted starter woes a few months ago and now I'm back with more.

'63 Falcon with a '68 200, Large Log Head, Autolite 2100 on a VI adapter, Header, DSII distributor with GM HEI Ignition (because my DSII module puked), C4.
This car starts instantly every time I hit the key unless it's been sitting for a few days, then it starts almost instantly.
Runs like a champ, I drive it almost daily... but I've developed trust issues.

I went through 4 AutoZone starters over the course of 9 months or so. Some of them had fitment issues, wouldn't work right until I backed the bolts off a bit. I gave up on AutoZone and went to NAPA.

When I installed new NAPA starter I thought the issue was solved, everything was great, no troubles, no adjustments.
4 months later it's having trouble engaging the flex plate. Lots of awful grinding noise and will only catch briefly. Fortunately, the car starts well so it usually takes less than 2 revolutions to get it to fire but I'm reluctant to take the car anywhere for fear of having to walk home.

Battery cables, Solenoid and Power cable to starter are new. Voltage is good, Grounds are good. Transmission is properly mated to the block, Flexplate is properly mounted to the crank. The car does not run hot, spark plugs are evenly colored.

Could it be the #6 tube on the header be killing these starters? I think I've replaced one Ford starter in 30 years of owning 60's Fords. Now I'm doing it every few months. Before I installed the header I heated it and beat some clearance into it for the starter's sake. I used a relatively cheap and thin starter blanket (a nice thick one wouldn't clear) on the last AutoZone starter but did NOT install it on the now failing NAPA part. I know plenty of people are using headers but I'm not seeing complaints of failing starters any header discussions.

I'll hit up NAPA for a replacement. I'll use the blanket on the new one and maybe pipe wrap on #6 tube. The good news is that with all my experience I can change a starter on this thing in about 10 minutes without getting my hands dirty.

Anyone else dealt with this?
Any suggestions?
 
Just took the starter off to return to NAPA.
One of the ears was broken on the housing. I guess that explains it.
I was careful on the install to tighten the bolts gradually and evenly, working around the circle of bolts.
It did NOT break on install as everything was great until a week ago.
 
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