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There is a lot of science behind this topic. So far it's not entirely sure if it's a feature or a bug

Short but ugly method: Install a new wire, let's say 10 gauge, from alt to black stud of ameter. And drill a hole going through the bulkheat so that you install ONE WIRE without any plug on its way.

Than try and you will find out if you also have other problems in your wiring - means it will melt somewhere else

Had it too: See here if u like



There are lots of ways to skin this cat... but I can confirm that this approach works with a stock or near stock size alternator... especially of you want to keep your wiring as near stock as possible. I made this repair on a '74 D200 in the late 70's. It ran that way without problem until 2002 when a rusty frame forced retirement. Lots more options though.