Sporadic Ignition Issues

[GIExploder]

Here's the background of the issue and the fix:

The positive cable running from the battery to the starter relay pulled free at the connection to the starter relay. I pulled the positive battery cable on out and snipped the red wiring running to the starter itself. From there I crimped a copper ring connecter to the positive wire running from the battery. I crimped a standard 5/16" ring connector to the wire that runs to the starter. Both connections have been sealed with electrical tape and shrink tubing. I managed to fracture the original starter relay so that was replaced without issue. Everything was reconnected and tightened down. Turn the key and nothing.

I have figured out the problem, but I don't know how to safely correct it. If I tighten down the nut connecting the red wire running to the starter from the relay with a socket (and NO I am not wrenching down), the relay will click and the starter will not function when the ignition is engaged. If I hand-tighten the nut, all the necessary connections are made and the starter works everytime without fail. The connection from the positive battery cable to the relay is tightened down and functioning without issue.

What's the deal? What am I missing here? I can't leave this situation the way it is since I am a volunteer firefighter and have to have a vehicle that can do at a moment's notice.

Anyone's thoughts? Thank you in advance!

 

[Verno]

One of two possibilities from what I read. #1 You got a defective "new" relay and need to replace it or
#2 The cable from the relay to the starter is loose at the starter solenoid, and when you tighten it down too hard at top, you turn it loose on the bottom.
Only other possibility is the crimp isn't fully mating on the cable to the starter.