"Rocky" <jcadellano.spam@optonline.net> wrote in message news:F%X4f.10134$1X1.9982@fe12.lga...

> Why would the main wire melt the terminal post on an alternator that is only
> in use for a couple hundred miles? Could it be the internal regulator
> failed causing the overheating?

Probably high resistance on the solder.

Protect your voltage regulator. Don't use your alternator to charge
a dead battery or a battery that never seems to be charged. It's
designed to keep the battery topped off. Don't use a hair blow
dryer while driving, or run the AC fan continuously.