With the starter removed, have someone slowly turn the engine with a wrench (you may need to remove sparkplugs) while you check the condition of the ring gear around the flywheel. You may have teeth missing from it which would just let the starter free-wheel.
Also check the starter's gear if you didn't do it before.
If those both check out OK, you may just have a corroded cable or clamp in the path to the starter.
It draws 100-150 amps when loaded with the engine and any tiny bit of resistance will drop so much voltage that the starter won't fully engage.
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