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Good to hear you got it together and working. Now insulate all exposed 12 volt connections and you should be good.

That circuit breaker will be perfect.

What are you planning on running? 1000 Watt inverter will draw over 80 amperes. That is #4. I would go with a circuit breaker over a fusible link because that is a lot of molten metal to capture in the silicone rubber jacket of a #8 fusible link. Yes, the alternators are wired with #6 and...

That would work too. It will draw off the front battery since this is also where the rest of the truck gets 12 volts for lights, fan, wipers etc. I run a lot of 12 volt loads off the rear battery, just to split alternator loads. And interior lights on the SECM box are series pairs of 12...

That diamond shaped power terminal on the driver side of the firewall is quite limited in power, I would not recommend applying any more load to it. The stock M1009 communications kit had two #4 wires to it, one is 24 volt #4 from the top bus bar and should be red. The other is a black #4 and...

You want 12 volts to the communication power on the rear passenger side of the M1009? Because restoring the under hood to stock made it 24 volts? Easy as running a #4 wire from the back battery negative to the rear communications power bars. Color code it red with black. Now you have access...

So now you need to check the starter to make sure of voltage. A 24 volt will not fling the pinion and make starter motor engage on 12 volts. A 12 volt on 24 volts won't last long. 24 volt starters draw half the current as equal 12 volt. So if the prior owner did a 12 volt conversion, you...

You have the root cause identified. The prior owner cut the 24 volt bus to 4 terminals, using the 5th terminal to "make" a 12 volt. Why? Probably for a 12 volt conversion. 24 volt starters are available as well as 27SI isolated negative alternators. My bad luck with local auto parts...

I see what happened. The wire you burned is supposed to go to the driver side 12 volt terminal block, not the 24 volt. You probably had the rear battery positive connected to the 24 volt bus, then tried to connect the back battery negative to the 24 volt bus. Hopefully this is what happened...

That wire is supposed to be connected to the front battery positive. The front battery positive is also the rear battery negative.