Am I correct in assuming that it still does it only when the car is already hot?
If so, heat soak still sounds like the culprit, especially if partially refurbishing the old starter helped but did not cure the problem. If it was me, I would just buy a new starter, and keep the old one as a backup.
*left field*did you ever check the timing/compression?
J
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'66 Mustang Coupe- AKA "Lenore" *on disability for a (long) bit*
'93 GT Mostly stock AKA "Fawkes"
Rice Haters Club Member #239
"I find your lack of faith...disturbing."
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