1997 ford ranger 4.0 wont start

replaced the starter and the starter solenoid located on the fender wall.
bench tested the new starter works great. so here's my problem when i go
to start the motor i get smoke from my ignition switch wire like it holding the
entire load and the bigger diameter wire that runs down to my starter isnt
carrying any but i used a multi meter and still am getting 12 v at the starter
and at the starter solenoid. and i also get a tick in my starter solenoid
located on the fender but it wont crank. this is a intermittent issue and
sometimes when i start the truck it starts with no issues today i couldn't get
it to crank at all had to compression start it. battery is good both starter and
starter solenoid are good