they had to put that on there to cover up their POS plastic intake

Maybe they put it on to CAUSE the damage? I haven't had mine on in 10 years and haven't failed a UIM yet.

Yeh I took the cover off now..good tip for better cooling guys. Makes it easier to clean the bay now too. Lightly sprayed the engine bay down but covered the new alternator.
High pressure wash to frame under PS pump and lines as it was nasty all around there.
The front rad/condenser was bug ridden too. Nice to have a clean bay etc again without oil leaks.

Ya this looks like it was stuck on a gas BBQ !!
Well I have no idea what to say other than after work, in the middle of no where...
I took out the Ancor marine 2 ga- wring job & wirez wafer fuse set up.
I am back to the stock wire for now..
I am wondering with summer under hood temps/loads & large diameter wire if I could wrap a hot dog in tinfoil around the wafer fuse & have it cooked in short order!
Overall plastic for this application is simply wrong. I checked with VOM still had full conductivity though.
I am going to get a battery cable or something today without a fuse & see how that does.

Wow, that sucks Art, was it somehow getting wet on that end of it?
I ask because it almost looks a bit corroded, at least I think I see a corrosion ring, of course I just woke up, and am having my coffee right meow.
I have never seen one of those melt like that, crazy stuff!

No to water getting in there. Just looks like terminal end overheating for what ever reason
Here is the backside of connector. May dissect it later...

Off looking to make or buy another wire...would like to get alt output/diodes checked as well soon.

No, you had poor connection right at that spot. Don't use that aluminum wire garbage. Use standard issue heavy copper DC wire. It carries more amperage at a smaller diameter vs aluminum.

BTW, when I drove over the road and wanted to heat something in a can, I'd pull over, put the can on top of my turbo, wrap it with aluminum foil and drive for a couple miles. Then pull it back off and eat.

Mike, you found another use for that plastic cover,,,,,,,use it to hold down your tinfoil wrapped sandwich on the 3.8'*, as you drive....

Ha ha, good one Gus!

Nope, my engine has been bra free for years now. Probably a dashboard in a Prius somewhere by now.