melting charge wire?!?!?

[silver01beetle]

so i have been having this problem for a little while now. the charge wire (the one leadin from the alternator to the fuse block on th top of the battery, the thick black wire), keeps melting the metal fuse that it connects to. it gets so hot, that the metal just breaks in half. after putting in the new fuse, it usally takes like 2 or 3 months for the fuse to break again.

i have an aftermarket volts gauge in my car and it usally reads at about 15-16 volts, which i kno is too high. i was told that this is prolly cause my voltage regulator is prolly going bad or is already shot. does this sound right?

if so i cn either just replace the regulator, replace the alternator which comes with a regulator, or what??? either way i was going to replace that charge wire as well, i figured with that much voltage running through it for some time now, who knows if it has weakened it or damaged it in any way! i went and picked up some 4 guage wire that i was going to run in place of that wire. does that sound like a good idea or should i just pick up one of those wires from the dealership? i just couldnt see paying $64.00 for a wire, and all it is, is 4 guage wire. i would make it the same length and run it in the same spot.

any insight to this problem would be greatly appreciated. or if there is something that i am missing or overlookin, please let me kno.

[silver01beetle]

no one knows anything about this???

[johnmichael]

i don't come here often, but i've had 2 melted fuse blocks on top of the battery. i had the same problem as yourself, overcharging all day long.

long story short, i replaced the 120 amp alternator that was on the engine with a remanned 90 amp, and the problems disappeared.