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Resistors only drop voltage when there is current according to Ohm's Law (V = I * R). The controller has limited current draw, this wire is at 24 volts whenever there is no glow plug activity. Now if you were to use a 7812 voltage regulator, the glow plug control card would never "see" any...

The best solution is to use 24 volt glow plugs and bypass the ballast resistor. That and better glow plug design that don't expand when they fry. I think the older HMMWV plugs should work. I know the Beru/Bosch glow plugs are like this, if they have an over-current issue, they fail open...

15 degree isn't extreme cold for the design of the CUCV. And the glow plug load is significant, especially at -40 temps.

The reason for use of 24 volt GP is to reduce the draw on the batteries. But since half the energy is wasted in the ballast resistor, there is only the balance of each battery during starting. Since each battery is independently charged by each alternator, if you go with the 12 volt tap for...