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did pull starter from car and bench tested as you said,bendix extended and starter spun.

Bench testing of the starter was OK but is it recieving enough juice when installed? & I would loosen the starter slightly & move it slightly & have a helper in the drivers seat work the key (safety first of course) & see what happens. We know the starter is good/we know the eng ain't locked up (iirc)/what is left is either not enough juice to starter (bad connections/terminals or inadequate battery & we eliminated the batt) or ground path (as mentioned) or there is a binding of some sort in how the starter is aligned to the block/flywheel teeth/mismatch there somehow but I'm thinking more electrical. Stay on it & keep us updated

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