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Ok, so I looked at the wiring again behing the genny. The small unmanaged wire branch had a fine razorblade thin nick in the sleeve that I could feel by hand caused by the sharp shroud (very tight spot to see without hoisting out the generator). I placed it in a sleeve and routed it away from...

I didn't notice the dash lights after losing the headlamps at nightime.

I didn't notice while driving a night and losing headlights. I assume they went off also.

Tomorrow I plan on disconnecting the generator sense wire, wiper motor, and light switch prior to another test drive in an attempt to locate the problem. The harness connections that go to the box are like new.

I took two trial runs and had the same issue that occurred once on each test drive around the block. At around 30mph, the lighting turned off and I heard a welding like sound in front of me possibly coming from under the dash or hood that last for a second or two. The sound stopped and the...