Uh-oh... I think we created another MONSTER...
just in time for Halloween too!
Another way to skin a cat...
Tom, one of the reasons many of us cut down the mounting BRACKET versus modifying the alternator... was to be able to replace the alternator "on the road, anywhere" without modifications.
Pardon me if you have already seen this, but this is the route many of us took:
http://www.network54.com/Forum/12159/message/1142890167/GM+alternator+conversion
Also scroll down to read my 2008 Update.
In this manner, as I said earlier, we can get a rebuilt anywhere, and with the lifetime warranty through AutoZone... never again pay a cent!
I u/s that this time of alternator can be had with a 100a output as well...
Lastly... tell us how the Voltmeter is working... as I thought the second wire had something to do with that...
Thanks for your idea and post though. You can still do this mod in the future if you like... and have an exchangeable core.
Lastly (again)... here is another way as well:
http://xwebforums.com/wiki/index.php?title=Alternator
Mostly his change was with the adjustment bracket and where it mounted.