So, after some time (ahem) I have my engine back in the car hopefully for the last time. Lights were all wired up and working. Brand new small gel battery, although been on the shelf for a while.

Car doesn't turn over.....

Power hold relay makes buzzing sound.
Start relay just clicks (If I'm lucky).

Measuring the voltage on the start relay, it shows 12v. When the ignition goes to the 'second click, this drops to 10.4v. When I go to start, 8.6v.

Where do I begin to fault find? Is the battery is dead? It has been fully charger, or not man enough - unlikely as people have used the same battery with bigger engines. I have put the car in gear and turned the engine by hand, all rotates freely (plugs are out).

Or do I have a bad load somewhere in the system that is taking all the current?

Engine is 1.25 Zetec SE, Ford ECU.

See below for my threads from ages ago about my last start attempts....

OMG was it this long ago

Hmmmm, familiar

It does sound like a knackered battery, but have you tried to measure the voltage directly on the battery, rather than on the start relay?

If I was doing this, I'd make sure that all the earth connections associated with starting are REALLY clean and tight. So - battery earth, starter to block (probably a direct connection, rather than a cable), engine block to chassis. Then I'd do the same thing with the 12v connections.

It does look like the battery though...

does sound like the battery.
simplest test is jump leads from a tintop or suchlike.

I guess I'll have to find a way - jump leads are 'missing' after a loan, and can't get tiptop close!!! Before, I just took the battery out of tiptop but both cars I have now would go bananas and loose all the settings!! Grrr!

Small gel batteries don't like just sitting on the shelf getting cold so it's probably that!