still got electrical probs(starter)

[panzertank27]

here's the story(short) 94, 6cyl, 270 000 kms,4x4(obviously).bought 2 years ago. 2 months ago, wouldnt start, thought it was the starter(not checked well enough) replaced starter(all work done by me, a backyard mechanic, barely) still wouldnt start, replaced battery(2 dead cells anyways),still not start(rechecked everything realized it was the relay ,it was clicking but not making a full connection)relay had melted just a little bit enough to interfere with full connection, scraped the melted plastic away so relay could complete connection,put relay back in she started right up, yahoo. not. 2 weeks later it melted again along with fusible link(about 6 inches of wire from ground terminal. replaced fusible link and have been using a wire to start truck (no relay im just putting it in nuetral, ignition on, clutch cancel pressed and using a wire to complete connection where relay is(yes i am a redneck, seems to amuse everybody who see's me.)so today after using a wire to start for about 3 weeks(working 6 days a week was planning on visiting junkyard next week cause i get a saturday off finally)was going to leave work today and the wire i use to complete connection burnt out like a fusible link(yes into my fingers the scars to prove it too... so for some reason the connection is heating up everyonce and a while (melted relay twice and wire into my fingers the last time..............why? does anybody know why its arching/ overheating that connection, im afraid to put a new relay in now because it might burn out that one (100$ new and hard to find in a scrap yard where i live) help please, thanks in advance.....

 

[RAD4Runner]

...thought it was the starter(not checked well enough) replaced starter...realized it was the relay...

It would help to first understand how the starting system works, instead of
throwing parts, time and money at the problem , and risk breaking more things. Here it is explained (First-gen's but same concept).

...it was clicking but not making a full connection) relay had melted...
...replaced fusible link and have been using a wire to start truck...
... so for some reason the connection is heating up every once and a while (melted relay twice and wire into my fingers the last time.....why? does anybody know why its arching/ overheating that connection...
... im afraid to put a new relay...

Fusible links and fuses are there to melt when something's wrong. Please stop doing anything until you have done some resistance measurements and found the short.

Which relay are you talking about? Got pics? Starter relay?

If starter relay, sounds like output of your starter relay is shorted to ground. Measured resistance of starter relay output to ground? Disconnected it from starter solenoid and measured resistance again?

Find connector on starter solenoid where starter relay output plugs into it? Measure resistance of that connector to ground. You should have several ohms, not close to zero. If close to zero, find out where it's shorted to ground.

Please keep us posted.