Dude! I just finished dealing with the exact same issue yesterday afternoon! I would turn the key....nothing. I would have to pump the ignition key 4-5 times before the starter would come to life. I could hear the relay clicking away. I tried the battery out of my uncles car and still the same. I replaced the starter and, to my dismay, still the same. Just for chuckles, I got down under the car, disconnected the starter main power wire from the starter and sanded it and cleaned the starter side terminal (it got a bit gunky during installation...that top bolt is the bane of my existence) with some fast orange. Reattached the lead and the car started the second the key hit start and ever since. Try a simple cleaning down there.
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91 GT Carb conversion, holley 600 double pumper, edelbrock performer intake, FMS "C" drop springs, march 1000 underdrive pullies, crane 1.7 roller rockers, GT-40P headers, bassani x pipe, american thunder catback, FMS 4.56's, msd aL6, trunkmount battery, A/C eliminator kit, 3000 stall tci streetfighter, AOD with transgo kit, A+ servo, 300M hardened lockup shaft, kevlar bands and 28,000 gvw trans cooler, 3 core radiator, 300 lbs stripped with a full interior
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