I had a very similar issue with my Cessna 150M. I replaced a 6 year old battery, and in the process discovered that I also had an underlying issue with either my battery solenoid or Master solenoid.
My hangar neighbor is a very knowledgable electrician. He owns a Marine repair facility on the Mississippi River. So he was helping me. We spent 3 days trying to figure out how to rewire the Battery and Master Solenoids to the electrical system.
The OEM solenoids have 3 posts, the new replacements have 4 solenoids! Now Kurt is a wizard with an Amp/Ohm meter, but he was still having a difficult time getting everything figured out. And yes we were using the maintenance manual and wiring diagrams. We were going crazy trying to get it all sorted out. But we did.
And even though I am an A&P /IA, I know my limitations and know when to get expert help. Both for electrical and welding projects.
I have gotten a little bit into this story with Ron, as he called me for some additional information that he didn't know. So I am familiar with the back story of this problem.
When I taught systems at TWA, Kalitta Air and Flight Safety International, I can teach you the principals of an aircraft electrical system but don't ask me to help troubleshoot it too deep. I would tell my students that in the final analysis the simple answer to any electrical problem and it's solution is... PFM. Pure Fu@k!ng Magic...
I hope Dalton and Ron get this all sorted out.
Ron "20"
A&P/IA
1976 Cessna 150M - N820ST
St. Charles Regional Airport KSET
Fly Safe... Fly Often...
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