StI'll having ignition problems :(

[Redassassin]

So this is what I've done so far go try and fix the issue:

New battery
New earth leads for battery and starter motor
Rebuilt starter motor
Replacement aftermarket ignition switch
New distributor cap and rotor (they needed doing)
New spark plugs
Tappets and timing professionally tuned

Whenever the engine seems to be hot the starter can't seem go turn the engine past a compression stroke, taking a spark plug out allows the engine to turn over, the timing isn't too far advanced as its only 8 degress and that's apparently normal for these engines, what else could it possibly be?

[JoKer]

done a compression test? or TK Leakdown test? (I'm suggesting or suspecting the motor might be a bit tired after the list above)

hope not OR you didnt mention Spark plug leads?

[Redassassin]

Haven't done a compression test, what happens is the car will start and run perfectly fine but once I stop it to start it again when it's hot the starter will sometimes do a single turn then stop, sometimes flicking the key a few times Wil get the starter cranking again, another method is forcing the motor to turn by putting it in gear and then the starter motor will start cranking again, when the car is running it's fine, doesn't burn any oil, runs well etc. I'll get some new HT leads tomorrow as they're cheap enough and I'll let you know the results

[oldschool]

It sounds like your starter motor has a dodgy armature and/or solenoid...were they checked/replaced when it was overhauled?

[TheMechanicnz]

Have you checked if your missing a tooth on the flywheel ring gear? That would cause it to lock up until it gets bumped over a tooth.

[JoKer]

fun "fact" a motor will always stop in the same place when you turn it off and yep ring gears may wear out in that particular high use spot (I feel its a myth but worth mentioning re the above missing tooth theory)

[Redassassin]

Collins auto electrical in hamilton, I was actually booked in yesterday for them to have another look at the starter but because of the fire at a. h. Frank's next door they've had to close up shop until they find a new location to setip and I'm not too keen to take it to amother auto electrician as I'll have to pay them where collins gave me a 12 month guarantee, I'll pull the starter out this arvo to check the flywheel and ring gear

[Redassassin]

It sounds like your starter motor has a dodgy armature and/or solenoid...were they checked/replaced when it was overhauled?

They bench tested the starter, said it seemed to be ok but did a service on it (new brushes etc)

[oldschool]

A bench test isn't good enough when servicing a starter motor...old armatures can get open circuits and/or short circuits in the coils, so each segment loop has to be checked with an ohm meter. There can't be ANY open circuits otherwise the starter motor won't have much power and/or won't turn at all when randomly stopped in a particular position..which sounds like what's happening in your case. 

[avengertiger]

which starter is yours? the old long type or with the solenoid on top of starter?

[Redassassin]

The one with the solenoid on top, my starter motor seems to be out of a mitsubishi though, it's not a Lucas one

[avengertiger]

made by mitsubishi thats correct but couldn't find any reference to being fitted to a mitsi when my one went on fire.but it will be the more powerful of the two starters.
check flywheel as suggested first.

[Redassassin]

Took the starter off and checked the ring gear and flywheel, both of them are fine, guess I'll have to wait for collins to setup shop again and get them to have another look at the starter, alternatively I'll just have to bite the bulet and pay for a third auto electrician to have a crack at it (already been rebuilt twice, so far the starter has had $480 spent on it)

[Redassassin]

So I've managed to fix the issue and i'm facepalming myself... the lead that goes to the battery (not the 12v to starter the other one) was so badly corroded the copper was just green, we cut it back a decent way and there was still corrosion, cut it back further, put a new terminal on and no more starting issues atm

[JoKer]

hah funny / not funny

glad to hear of a result at the same time : happy motoring