I measured the voltage drop from the negative battery terminal to the front frame ground (the radiator support bracket) with my cooling fans running. The drop was 0.0150 volts. Each of my fans were drawing 7.0 amps (engine not on just running battery voltage).
Frame resistance = 1.07 mohm. That's a "mill" not a "Meg" ohm.
So even with OEM fans drawing 40 amps and the headlights using the frame ground (20 amps) you still would only drop 0.064 volts on the frame ground to the fans and headlights.
So it was not voltage drop that made DMC decide to run ground wires for the headlights. Also to note, there is no reason to run a copper wire end to end of the frame unless your just using it as easy junction points.