Alternator short

[bloky]

Hi all,
recently i have had electrical issues where i was getting irregular voltage, subsequently i replaced the voltage regulator.
On the weekend gone the charge light came on whilst driving, disconnecting the battery would cause the engine to stall. So i bought a brand new alternator with a 50amp (instead of 40amp) output. Same plug, external regulator.
Installed it, started the vehicle, and it ran for about 30secs before i could see smoke and a smoldering wire coming from 'E' wire connector plug at the alternator. Checking with my multimeter, im getting a battery voltage reading to the positive terminal on 'E' and 'F' connectors, in the wiring with alternator disconnected. Is this right? surely its not the extra 10amps in the circuit causing the burnt wire??

82 hilux 4x4, 18rc.

[bloky]

Had a bit of a play, replaced the melted and adjacent wiring, rechecked everything, no obvious shorts.
Started her up, runs without melting the wire now, not sure if this is just the heavier wire, as the charge light is still on while engine running and alternator working.
Going to try another voltage regulator to see if that helps.
Anybody have any other ideas?"?

[thechuckster]

thought about upgrade alternator to a unit with a builtin regulator? As per this or this thread.