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As my follow up. I installed a new rear battery and the truck fired right up. While installing the new rear battery I temporarily connected the all battery terminals except the back battery positive (recreated the conditions when the OP drew an arc to the firewall). From that back battery...

Great news. :grd: Glad you solved it and thanks for the after action report. This will help others with similar problems. Just goes to show one can have all the proper voltages in all the proper places but the system fails under a load. In the commercial electrical industry we use thermal...

I went to start my M1009 last weekend. Turn the key on (I have 12V GP conversion) and everything was great. Turn the key to start and nothing. All lights go out, voltage drops to nothing on the gauge and the starter motor made maybe half a revolution. Turn key off, wait, turn key on, all...

This came from warthog. Looking at the 24V bus there is the lead to the battery that you had disconnected and the there are two leads to the passenger alternator. The negative side of the passenger alternator is +12V above the vehicle chassis. I am thinking that this 12V is what sparked.

Is this drawing an accurate representation of what happened when you were cleaning the battery wires?

I am still trying to figure out what shorted. I have not gone through the schematics yet. Just flying by the seat of my pants here but if you remove the back battery positive cable is there still voltage on that cable when measured to the chassis ground? I need to change my back battery so I...

Too late but for the sake of others the front battery ground should be the first wire disconnected and the last wire reconnected when doing electrical work on the CUCV (or any other negative ground vehicle for that matter). Was that terminal that made contact with the chassis the back battery...