Another thing to consider is voltage drop. Like Fred suggested, possibly in the headlight switch, ignition switch, or the wires. What you can do to bypass the problem: Run a wire from the extra spade terminal on the starter to a pushbutton switch that you can reach from the drivers seat, the other side of the switch to the + on the battery. Turn key on, push the button to start. To test this theory on the cheap, just run a wire off the starter terminal to where you can reach the battery with the other end. With the key on, touch the end of the wire to the + battery. (Use blocks and make sure it's in N, it will start. It's a cheap fix, but I've been running it on my bug for 6 months. Robb