that part about melting your ground strap has me worried. with your neg cable directly bolted to the block, you should have no problems with grounds. something melting the chassis ground strap is a bad serious draw. find it.
also go to the list of threads, and arrange by most responses, and go through the thread by andy "won't start for anything"
I am SURE you will find something in that thread to fix your starting problem.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!