Solenoid Heat!:(

My 3B has been converted to 12 volt system by PO, when upgrading to pertronix this weekend I noticed the solenoid getting extremely hot very fast when turning the engine over! any ideas on what might do this?
I may replace the solenoid and see if that works! OR go back to stock floor starter switch (I kinda like this idea). I read some place that you can run stock starter switch with 12v system and not use the solenoid!?

Also, it seem that i may have a ballast resistor in the system, when i turn it over i get low spark. when i use a 12v jumper wire to coil i get great spark. the prob. is i cant find the resistor? I followed the wires from batt. to ignition and all around with no luck! I have a tilt/telescope steering assembly from mid 70's (i think) Cadillac could it be in the steering column?

any ideas/help??:?

 

I wonder if the starter is still 6 volt, left over from the conversion. That might cause the heat-up of the solenoid. You can use the 6 volt starter as long as you don't grind on it for any length of time.
Bad cable connections can cause heat/resistance problems as well.
Your low spark problem could be in the column, if you have a pinched or damaged wire. Your own test proves something is not right.
the ballast should be external somewhere: firewall, on the coil, etc.
all I can think of

 

The heat in the solenoid start right away (no prolong cranking of starter) it can get red hot in 6-8 sec of use!

I don't know about the starter 6v or 12v!
Thinking of bypassing the column switch and the solenoid and just using a toggle switch and floor switch!? This (i think) will take care of the voltage prob. and bypass any prob. in column and wiring that i cant find!

But, i don't know if the floor switch can work right if the starter is 12v, and i don't know if the switch can take the 12v?

 

thinking logically (this always come back to bite me) the switch is just a switch; like putting the ends of 2 wires together
I don't think 6V or 12V is the issue

 

Hi, Here is a thought. My uncle wired a set of offroad lights through a solenoid but used the opposite contacts. He put the heavy amp draw through the switching contacts and the 12v to opperate the switch through the heavy contacts. Got hot really fast. Does it have a poor ground.
Hope this helps

 

I'll check on that! and I'll recheck contact wires on starter as well!!
I just put corner panels on so right now I'm putting the tail lights back in and fixing the dash patch the PO did. so i should get more time next week to follow up more on the solenoid!!