So I convinced myself that the problem must be bad grounds.. so I added grounds to the generator body, and regulator housing and returned them to the body and the battery.. nope: no charge. After 4 regulator changes and adding a ton of grounds, the generator was all that was left..I did have another one with the wrong pulley in my attic, so I got it and gave it the motor test. Spun on the bench just like the one in the truck did. I pulled the installed generator and swapped pulleys and spruced up the paint on the spare. I put it in and the charging system works as intended. And the generator I pulled STILL passes the motor test. So I am pleased that the system is working properly but vexed that no real cause was found. I guess I can chalk it up to an intermittent situation or maybe an internal loose connection within the generator.
