I'm pretty sure it's the switch that's bad. Now.

I just got arc from the large wire to ground
while disconnecting known good timer.
(ignition off, key removed)

Would this also fry the timer, and drain the battery
without blowing the 80A fuse?

What's the PITA factor on the ignition switch replacement?

Thanks,
Bri

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'85 300DT 170K
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'83 300DT 252K executed by non-driver
'68 F-100 138K sold (why?)