Charging System

[PKRWUD]

It sounds like there is too much resistance in the starting circuit. What gauge cable are you running from the battery pos. post to the starter relay? Where do you have the battery neg. cable grounded?

There's corrosion around the negative post

This is caused by a broken battery post seal. Around each battery post, there is a plastic seal which keeps the acid in. These seals are often broken by improper battery cable installation and/or removal. Hitting the battery cable clamp with a wrench or a mallet while trying to get it over the post will almost always result in a broken seal. Once the seal is broken, the battery is defective. The seal cannot be repaired. This doesn't mean the battery won't hold a charge, but it will leak acid, which will deteriorate all metal it comes in contact with. This is what causes corrosion around and on the battery cable clamp at the post. As soon as this starts, the cable is forever becoming weaker, and is becoming a source of resistance. If you replace the battery, you also need to replace the cable that has signs of corrosion on it. The acid can be neutralized with a formula of baking soda and water, but if the cable has been affected for a month or longer, the deterioration justifies replacement.

In either case, make sure that the post and the inside of the cable clamp have been cleaned with a battery terminal wire brush.

Take care,
-Chris