Finally we think we have it fixed. Time will tell.
As mentioned before we replaced the ignition switch after an electronic diagnosis. Once that was replaced we still couldn't get it to turn over. A friend said, when you replace the electrical switch you should alway replace the actuator pin assy. So another $40 later and a new actuator, he started right up.
Hopefully I'm done with this issue.
Still doesn't explain the volt gauge pegging at 19volts...unless there always a ground problem we fix during the diagnosis. Again time will tell.
Turns out the slot inside the switch was no longer square so the actuator couldn't turn the switch everytime. I couldn't see anything wrong with the poc metal actuator drive but it must have been round as well and would not snugly fit in the switch.
Anywho it's fixed.
Thanks for the replies to frango.