Ignition key bypass
Maybe I missed it, but did you try bypassing the ignition key switch by applying 12V directly onto the starter motor solenoid?
No experience wuith it myself, but as I wrote earlier, I do hear from other owners that the contacts of the ignition switch can get weaker, causing a too weak current to the starter motor relay to switch properly. A new ignition barrel is the solution, but expensive if available at all. Otherwise use an auxiliary relay.
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