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70 roadrunner....
If I run an 8 gauge wire from the alt (batt post) to the starter relay (batt post) with a 12 gauge 30 amp fusible link. Then another 8 gauge wire from the starter relay (batt post) to the positive battery terminal again with a 12 gauge 30 amp fusible link I should be good...
Actually, the difference between 5 and 20 isn't as much as you might think. If my math is right, at 900 rpms, that means the spark is happening 2/1000ths of a second sooner at 20 versus 5.
Check fusible link at the bulkhead connector. Then the next thing I would check would be the starter relay. Use a light or meter to trace where you have power and where you don't. And trace those two random wires you connected to see if they do in fact belong together.
When you say dash harness... could you be more specific? Is your ammeter still connected or have you disabled that? Did you check the bulkhead connector for any funny business going on inside that?
As wilerrobby suggested you probably have a wire with current touching ground somewhere...it...
Red's right. I ran around that way for a year with a ground there. Not because my NSS was bad but because the rubber boot was hardened and kept falling off. Finally got a new one and removed the ground.
Just pull off and reseat the bulkhead connections. Check for oxidation. If they are oxidized spay with electronic cleaner, scrub with a wire brush, put some dielectric grease on and reconnect. Also check coil connections, battery connections etc...
Clean your bulkhead connections for grins and giggles. That would be the mass of wires that connect to the firewall. Remove them....spray metal contacts with electronic cleaner and brush the metal contacts with a toothbrush then reclean with electronic contact cleaner. If you have dielectric...