Ye olde wiring harness? When to replace?
My idea is why don't you just take the problem out of the equation, while keeping the factory internal wiring, just lowering the load. IE- find a fuse/relay underhood block out of a mid 90's model Cherokee
Some of us have done exactly that, but the problem "is not that simple."
FIRST you have to fix the ammeter problem. Even Ma knew this was a weak point, ya want proof?
Google up what is known as "fleet wiring." On the cars with 65? A factory optional alternators, Ma did an improvement in the wiring, running the ammeter wires through separate grommets in the bulkhead. That right there solves a bunch of the problem, because the tiny bulkhead connector terminals were NEVER designed to carry upwards of 40-50A, and now that they are 40 some years old, even the ignition / headlight circuits give trouble.
I don't use a factory harness anymore, but I DO have a Voyager fuse / relay panel under the hood to run some of the loads, including headlights.
So what you have as a solution is not exactly new It IS a good way to go.
But the rest of the problem is, "if you leave" the factory harness there and simply try and improve it, you STILL have poor connections in the original fuse panel and at other connectors in the harness. This of course varies from car - to car.
