Update #2:
I replaced the broken 2.5mm² Bk/Vi wire with a new, external 12-gauge wire. I had some stranded copper THHN, 90°C rated, Southwire Made in USA normally used for commercial wiring (not automotive applications). I briefly looked for automotive wire with silicone or other higher-temp ratings, but all I could find was either high priced name brand stuff (>$1/ft, usually min 100' reels) or no-name junk on Amazon that I don't trust the quality of the wire (may not be copper), nor the size (likely undersized), nor the claimed insulation rating.
With the new wire installed, the electric fans are back to normal operation. I measured ~12A draw via Fluke clamp ammeter with the engine off.
Interestingly, I also learned that the typical area where the wiring harness overheats and fails at the resistor, is where the high speed fan wire joins the wire which goes to the fans. It seems the resistor itself may not be the problem. Or possibly, it's that the terminal location is an issue, with the 2-wire connection at the top of the resistor (more heat) vs the bottom. Makes me wonder if the connections were reversed, if there would be the same 'overheating' issue. I had repaired that broken wire years ago and the old repair was still intact. The recent failure was completely separate, buried somewhere inside the harness.