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85 DL Wagon Alternator/Charging problems 200 1985

I am a virgin to the volvo world but recently purchased an 85 DL wagon with 199,000 miles NO RUST, dents, etc for a mere $800.00. Enough of the good news...four months and 4000 miles later, I ma fighting the alternator battle. I have replaced it with an alternator from AutoZone (is that a bad call?) and still am having charging problems.
I looked today and found the red wire going to the alternator to be rotted and broken (the culprit I believe) What is IPD I keep reading about? I believe I need a new wiring harness and dont know how to 'roll' my own. So my questions are:
1) what/who is IPD?
2) how difficult is the wiring harness to replace?
3) what is the average life expectancy of a DL with 203,000 miles which runs like a top? (The tranny was replaced at 160,000)?
Thanks in advance for anyones advice...

shane






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