Maybe amp problem? Battery arcs.

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Amplifiers will cause a small arc when connected if the capacitors in the power supply are flat. Not enough to weld with as described, but arc nonetheless (bigger amp=bigger arc). To charge the caps slowly: put a test light inline with the battery lead; when the light goes out, the amp caps are charged. Now if the light DOES NOT go out, you have a short or draw.
 
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