Made another tweak to the headphone setup.
Changed to a 2K, 3W, 1% tolerance wirewound resistor set.
Wirewound resistors are supposed to be much better than carbon film resistors. The only downside is cost compared to carbon film, not an issue here.
This took the alternator whine down to near zero, (the infinity system in my jeep has more whine),
made the volume level run at close to the same number of bars as the external speakers,
greatly improved bass response,
and the speed variable volume adjustment works near perfect.
I also switched to SHURE E4C headphones, much better separation and bass response.
To summarize:
Use the low power leads off the radio
Only use the ground from one side (I used the left ground)
Put a switch in the external speakers, (the only time you will now use them is when cleaning the bike)
Use a 2K ohm, 3w 1% tolerance wirewound resistor in the hot lead off of right and left sides
Use shielded cable for the earphone jack.