Lots of info here! To answer a couple of your questions: I replaced all the wiring and installed a fuse block (Hot Rod Wires) a few years ago and have an 8 gauge wire running from the starter to the amp gauge (I am aware of the arguments for and against the use of a amp gauge, no need to repeat here) then to the fuse block. Same size also from the generator. Wire gauge is plenty big for my needs as I have added no additional loads to the system (heater fan, lights, ignition, and horn is about it). My main reason for installing the solenoid for the headlights is because one of my headlights burned out and the only local replacement I found has a wattage rating 60 watts for the high beam, but the specs for the truck say 50W. I did not wish to be always worried about what that extra wattage/amperage might be doing to the headlight switch (all the wiring is newer and larger than original, so that was not my concern), I decided to put in the solenoid to bypass that switch. Maybe it is necessary, maybe not; but I feel better about it. My question is about the main feed to the relays from the battery. The wire for this part is way too short to make it to the battery without adding in a section of wire. So would it be better to run a longer piece all the way to the battery, or a shorter section just to the top pole of the voltage regulator. It has 12 volts all the time and is a 8 gauge wire. I can’t think of what would be wrong with it, but maybe somebody here knows of a reason.
Thanks,
Lee
