Simon, thanks for your help with this thread!
Regarding the cables that appear to have heat bonded together, these were inside the split loom covering and were not touching anything hot. The covering was unmarked.
There was evidence of overheating where the cable entered the loom connecting plug as well. Hence my opting for what I understand is a lower consumption fan.
The cable that was damaged by friction was the positive feed before the fan connection on the chassis. This had rubbed on the rear of the projector head light.
I have now reinsulated this cable and tried to resite it as best as I can.